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  Topic Review (Newest First)
04-09-2019 03:13 AM
mistamun For anyone using thread as a reference for the 116 transaxle, keep in mind that the photos in the first couple of pages are from 105 boxes. The 1st gear mechanism in the 116 is assembled the other way around as the gears are meshed in the inverse direction. It should be obvious by the angle on the larger notch

105:


116 (early):
01-09-2019 08:02 AM
Norseman50
Quote:
Originally Posted by 60sRacer View Post
There are NO new or NOS dog sets available!

Robert
Robert,

Thank you for conceiving the concept, (and posting the method of achieving) a synchromesh first gear for our Alfa Romeos.

I implemented this improvement when I rebuilt the gearbox in my Spider and it worked perfectly (and still does by the way). I used the best spare dog gears I had between my box and a donor box because at the time I did the work (4 years ago) there were not any sources for new dog gears. But it seems that Centerline has found a contractor capable of producing them, and although I have not personally tried this new batch, Centerline is offering them to the public now (but at a premium).

https://www.centerlinealfa.com/catalog/gear-dog-ring
01-09-2019 04:36 AM
60sRacer
Quote:
Originally Posted by Norseman50 View Post
Yes. You have set up the synchro bits correctly.

I have not personally tried the fix using the same 1st gear dog (with 2 openings) because mine were always shot, but you should not have a problem with the way you have it assembled.
I ( the originator of this fix) did this to my 1600 transmission in 1971. I've driven it at least 100,000 miles since with no trouble. And I did not change the dog tooth set, so mine is exactly like yours.

You should note that while you have your TX apart, replacing the 1st and 2nd dog teeth is a good idea. Typically the sharp engaging teeth get worn down on these two gears way ahead of the others. You can get good replacements from APE (see suppliers list), or you can swap your 5th gear dog set - which is usually nearly pristine - for your 1st or 2nd gear set.

There are NO new or NOS dog sets available!

Robert
01-04-2019 12:57 PM
Micoal Hello All

New to the site and in the process of making the mod. The thread is informative and amusing. Oh, the Milano gear box will sit in a GTV6 frame. Can't wait to drive it.

Thank You
09-22-2018 07:22 PM
r-mm I'd like to merely say thanks to everyone who posted on this thread - and the the fix was a stunning success! Less grunch than a modern car after the fix and a fresh fill of redline.
04-28-2017 07:28 AM
factotum
Let the Good Times Roll

Thank you 60sRacer and Alfar7, and everyone else who has contributed to this thread, for your great instructions. I have just pulled the transmission from my 1989 Spider Quad to replace a leaking input shaft seal and leaking differential seal. I will have to make the castle nut removal tool and have a 30mm socket for that purpose.

The second gear does grind a bit if shifted too quickly. You have given me the self-confidence to do the first gear fix and have a good look at the second gear. Fortunately, I bought a spare transmission a few years ago that I can use for any needed parts. I will post an update once the operation is completed.

Regards,
Chuck

1989 Spider Quad in Alfa Red on grey, 49k miles
09-18-2016 08:35 AM
AlfaDuc I agree with the comment on the weird spring in the Milano 1st gear synchro. That spring actually broke in half in my transaxle and jammed the synchro. Made it impossible to shift into 1st gear. Had to disassemble the tranny and synchro to fix it. Stupid design.
Jim
09-17-2016 10:06 PM
Gubi
Quote:
Originally Posted by Ennio View Post
I´ve been reading this thread with great attention as I am planning a tranny rebuild. I own an Alfetta and wanted to know if this mod applies for transaxle cars.
The Milano, at least, had a different setup. There's this goofy spring-loaded bit on first gear (parts 5-7 in the diagram) that theoretically engaged the synchro but didn't actually work well at all in my experience.
09-17-2016 08:00 PM
Ennio I´ve been reading this thread with great attention as I am planning a tranny rebuild. I own an Alfetta and wanted to know if this mod applies for transaxle cars.
08-09-2015 07:04 AM
Alfar7
Bearings

There is nothing to be gained!
08-09-2015 02:01 AM
Rosenmöller
Quote:
Originally Posted by slyalfa View Post

The next thing I see is somewhere in the late 60's Alfa put in needle bearings on 5th.
can the needle bearings be used on the rest of the gears too??
Just found this one:

http://www.alfabb.com/bb/forums/alfa...5-gearbox.html

Salutations

Bernhard
07-24-2015 08:26 AM
r-mm Thanks - appreciate the confirmation.
07-24-2015 08:18 AM
Norseman50
Quote:
Originally Posted by r-mm View Post
Hi all

Can someone lay eyes on my version of this fix - I replaced both sectors and both arcs from a 2-5 style synchro into my existing 1st. Looks right?

Old 1st gear pieces off the the left, canabalized synchro to the right.

Thanks
Yes. You have set up the synchro bits correctly.

I have not personally tried the fix using the same 1st gear dog (with 2 openings) because mine were always shot, but you should not have a problem with the way you have it assembled.
07-22-2015 08:19 PM
r-mm Hi all

Can someone lay eyes on my version of this fix - I replaced both sectors and both arcs from a 2-5 style synchro into my existing 1st. Looks right?

Old 1st gear pieces off the the left, canabalized synchro to the right.

Thanks
07-05-2014 11:00 AM
Joe Papa Sr
Quote:
Originally Posted by 60sRacer View Post
Will we ever understand our quirky Italian cars? Do we love them BECAUSE they are so weird?

Robert
Who knows- but I know Im "stuck" (willfully??)with the car, and will never sell it- it IS cool, but yes, they can be a pain.
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