They are easily repaired by someone who knows how to weld aluminum.What I think we need is to encourage the usual Alfa suppliers to come up with a remanufactured box that is made of sterner stuff. When I removed my old and now disgarded box from my car it had all the usual cracks described by Diogenio. It was no small task tracking down a replacement but I eventually found one.
It's more than likely true that it's a bad design and that they will crack over time. Keeping them properly maintained decreases the likelihood of this failure. If the box has the proper lubricant in it, the worm drive will move more freely which decreases the stress applied to either end of the shaft and box.Even when the screw is BRAND NEW and totally bathed in oil, turning the steering wheel in either direction puts high peak compressive and expansive forces toward either the front or rear ends of the box, depending on rotation. This "immoveable" object (the casting wall) is what allows the torque to be transferred to, and move the vertical shaft and thus your wheels. This is a simple principle. Remove the walls and the screw would in fact go out the front or back of the box, while the wheels stay put.
Even boxes that have been well maintained develop stress cracks, and some have gone onto total failure.
Search the forums for evidence of ZF boxes cracking or failing. (BTW, they require oil too). You wont find many, if any reports of failure. Quite the contrary for the Burman boxes.
Believe whatever you want to believe. I guess it makes people feel safer.
What he said.Thank you and good night.
I would be interested in such an action.If you are concerned, a group of guys can perhaps contact Jim to have him produce a short run of the steel reinforcing plates, and the DIY guys can install them at home. I had Jim rebuild my entire box for that cost, so the plates alone would be much cheaper.
Well that's embarrassing! I meant dyepen but maybe those new high power aluminum magnets will finally make Magnafux practical....
Rich: Magnafluxing does not work on non-ferrous metals, like aluminum, hence the use of liquid dye to find the cracks!
Therein lies the rub, eh? If your premise is that these boxes are a bad design (which I don't agree with) or that they are passing their useful life (which I do believe) then finding "a good used box" is like finding a "rust free" body.... If one begins with a good used box...
On this I totally agree!...If Burman had just made the front and rear bosses 50% or 75% thicker...
I will take one. Please PM me regarding payment.After a long search to find the seal (28 X 42.4 X 8) for the ZF steering box I purchased a "large" minimum quantity of seals from a supplier. If you are in need of one/many I want $13.00 USD shipped within US and $15.00 USD each everywhere else. I will also put this ad in the FOR SALE section.
I believe that Alfaholics offer replacement Burman box cases for £695.00. See: Montreal LHD Steering Box Case | Classic Alfa Romeo spare parts and accessories Yes, that item in their catalog is for a Montreal, but I seem to recall someone on the BB saying they contacted Alfaholics and learning that they could also provide a version for a 105. (for extra points, how do the Burman boxes for Montreals differ from the ones used on 105's?)What about having new castings made.....instead of a billet machining? Anyone out there interested in pursuing this?