I'm upgrading the 1300 in my 1972 GT Junior to a 2L, and while I'm at it, I will be rebuilding the transmission. I thought it would be helpful to the rest of the crew to post pictures and details on the process. Once completed, I think it would make a good sticky...
I have rebuilt engines and transmissions in the past, but this is my first Alfa 5 speed. The plan is to do this in my garage with readily available tools.
I believe this to be the original and un-rebuilt transmission from my car. It was working fine, minus the periodic 2d gear grind. I plan a stock rebuild but with lightened gears.
The Alfa 5 speed was introduced in 1959. It remained basically the same until 1967, when the hydraulic clutch replaced the mechanical clutch. Note - the 1967-1968 GTV 1600's and Giulia Supers still used the mechanical clutch. The hydraulic clutch bellhousings are easily spotted; they have a provision for mounting the clutch slave cylinder.
From 1967-1972 the gearboxes are the same, and can be identified by the front bearing on the input shaft -- it's secured by a circlip/snap ring, and the rear drive yoke is secured by a 32 mm bolt with is locked by a flanged lock washer. THIS IS THE TRANSMISSION I AM REBUILDING NOW.
Beginning at some point during model year 1972, the transmission was changed slightly -- the front bearing and rear flange were secured with 32 mm nuts that have a built in flange; pictured in a later post. The flange is peened into a small groove in the shaft to keep it from moving.
I bought the car several months ago. Here's what it looked like before I completely disassembled it.
What I will not cover - transmission removal, clutch fork and throwout bearing removal. That's already done. I have also drained the trans oil and given the exterior a good cleaning.
The victim, seen here hanging off the backside of the 1300...
Another "before" picture...
References (to be completed)
Alfa Manual...check with AlfaBB member PapaJam
Alfa BB Threads
Gear Lightening - http://www.alfabb.com/bb/forums/gt-1...ightening.html
First Gear Crunch - http://www.alfabb.com/bb/forums/gear...-gear-fix.html
Sources for Parts (to be completed)
Centerline - https://www.centerlinealfa.com/gearbox
- seals, bearings, bushings, dogtooth gear, transmission mount, sliders, synchro rings, etc.
Alfaholics - http://www.alfaholics.com/browse-par...erential-part/
- seals, bearings, bushings, transmission mount, sliders, synchro rings, 5th/reverse selector lever, close ratio gear sets, etc.
Alfa Parts Exchange (APE) - used parts
Tools Needed (to be completed)
Socket or box end wrenches: 1 1/4" or 32 mm socket (12 point) or box end wrench with deep offset; 19 mm, 13 mm
Ratchet and extension
Snap ring pliers
Non-marring hammer (dead blow with plastic face, hammer with rawhide face, etc) - strongly recommended
Impact driver (not required)
Impact screwdriver (not required) - http://www.amazon.com/TEKTON-2910-2-...ct+screwdriver
3 Jaw Puller...
Brushes, solvent, pics, etc (for cleaning the exterior)
Hydraulic press (not required)
Anti-Seize - Permatex - strongly recommended
Kroil or 50/50 (auto trans fluid/acetone mix) strongly recommended for loosening bolts
Seal Removal Tool - makes easy work out of removing the...wait for it...seals! http://www.amazon.com/Lisle-56750-Se...+remover+lisle
Also strongly recommend a fairly large and well-lit place to work. Here's my workbench...(pic to follow)