[JEFFDHURLEY1]

Success !!

The bolt is out and the transmission has been muscled from its mount and is soaking in degreaser I am searching for a local shop to re surface flywheel but as been hard to find here in the big city of Mineola

the flywheel and clutch area were dry just lots of dust
friction disc worn just to the rivets but no damage to metal surfaces

the bell housing has a lot of oil in th bottom but I think it came from blow back from the huge engine leak fixed in spring ( had a 1/4 gap in the cam cover gasket losing about a quart a week ) working its way around the inspection cover
will be ordering both transmission shift lever seals

I put on a new Slave Cylinder after the leak repair and its boot is already torn
does any one know where a replacement can be bought without buying the whole unit
wish me luck
hopefully will be going back in this weekend if the weather holds

 

[ghnl]

Make sure the machine shop understands the pecularities of the Alfa flywheel. If only the friction surface is machined the clutch may slip once assembled.

The pressure plate bolts onto the raised lip. Both surfaces should be equally machined to maintain the correct depth of the step. (dimension 'B')

See: Clutch Slipping

 

[ghnl]

And when you re-install the flywheel it must be bolted on the crankshaft correctly. It is not doweled & can thus be bolted on in 6 different positions. Only one is correct...

See: Installing Flywheel

 

[JEFFDHURLEY1]

transmission stabbed went in first shot and mostly bolted up with a few of the harder bolts left shoulder bolt on starter in the right position . transmission boots on order
found old boot for slave cylinder .. so slowly reversing the removal
will prob fill with oil next week
thoughts : spirex or redline or is there something at the local auto shop I can by and not have it shipped in from afar .

 

[ghnl]

Shell Spirax (I found some at a Pep Boys a couple of years ago) or Redline 75w90NS. Most other 'normal' gear oils may not allow the synchro's to function correctly.

 

[JEFFDHURLEY1]

engine started first shot .. after all I had undone getting to the bolt I was concerned

new boots and console re - installed ( had to "modify" the hard rubber shell between the inner boot and the metal shroud the front of it was well busted and hitting the gear shift lever looked like it had been for a while ) ) any way all console back in and no fouling of shifter on console with new trans mount
replaced clutch pivot with new form emmas ( sp) it was EXTREMELY tight going back in but all hooked back up now clutch pedal still about one inch under brake pedal
ran out of daylight before checking length of master cylinder actuation rod once checked will bleed the clutch tonight and then fill tranny with new spirax . then comes the test drive cross fingers

 

[jcslocum]

Great job! Starting on first try feels soooo good :-0

 

[bianchi2]

on the slave cly boot..i like to use the clutch master cly boot.. heavyer built..

 

[JEFFDHURLEY1]

clutch bled final exhaust hooked up
still on jack stands
spirex will be here tomorrow so transmission is still empty
but was able to clutch and shift gears fine with no grind but did not do long and with no load
master cylinder rod only 5" not 5.28 explains the low pedal will adjust soon

but do you think a test drive after transmission is filled will hurt anything with the rod being bit short ? need to be parade ready by Saturday

 

[JEFFDHURLEY1]

Since I hate an unfinished thread

Nothing worse than searching for a thread finding the problem and having no resolution. So, Starter in no issue and remembered the spacer. Flywheel ground per spec and installed ( thanks for warning to mark for proper timing )
torqued and installed new pressure / friction plates and throwout bearing as well as trans mount and boots on transmission. I did put a thin layer of high temp brake grease ( wont run )on the shifter slides , tightened them up a bit and feels much smoother
had to put a washer under transmission mount bracket to bring tail down a bit so shifter would not foul console with new mount .

bolted all up double checked all vacuum lines undone for starter bolt as well as checking all grounds
engine fired right up
installed new clutch pivot as it gave out just as the clutch started slipping (thanks for all the tips on this too and the pictures )

bled clutch with bleeder at 12.00

filled with fresh spirax
and drove !!!!

First time since I have owned it to drive with a really good clutch bite
I have not yet stopped grinning

Highs this weekend in the 70's so after Christmas Parade Sat Morning it will be time to go see the fall leaves before they are all gone
thanks Alfa BB and to all who's tips made this job a bit easier
now since I have replaced a water pump including double nutting the studs and have done a full clutch replacement including cylinders and flex lines and new trans mount bushings as well as rear wheel bearings am I considered Alfistii ? or do I have to do engine mounts first

 

[ghnl]

since I have replaced a water pump including double nutting the studs and have done a full clutch replacement including cylinders and flex lines and new trans mount bushings as well as rear wheel bearings am I considered Alfistii ? or do I have to do engine mounts first

How noticeable are the scars on your knuckles? And have you learned at least 3 new cuss words in Italian? If yes to both you may be an Alfisti. Do you frequently browse Craigslist looking for another project Alfa? If so then you are addicted... (ALFA = Always Looking For Another)

 

[Tifosi]

I dunno man, mounts are pretty high on the pre~requisite list

 

[ghnl]

I said may be an alfisti. Read all the words.

 

[Tifosi]

I dowanna it are am makes my head hurteded

 

[ghnl]

words, words, words

 

[jcslocum]

I dunno man, mounts are pretty high on the pre~requisite list

Just the passenger side really. DS (left) is cake and any Fiat owner could do it

 

[Tifosi]

Just the passenger side really. DS (left) is cake and any Fiat owner could do it

Well, yeah, of course.
If one counted just the left side alone, one might as well say that pumping your own gas makes you one of the elite.

Now as hub bearings were mentioned, that is indeed a fair bit of work and not to be scoffed at, but it'd definitely been money in the bank if a pinion seal were included in that package. (oooh, missed it by ->that<- much )

 

[JEFFDHURLEY1]

SIIIGGGGHHHHHHHH!!!!!

Yep on Pinion seal with self modified tools.
Knuckles ? the folks Sunday asked when seeing my hands , If I had been trying to stuff butter up a bobcats butt with a hot knife . that and the few scars from working in and around Piaggio P.180 aircraft a few years back ( not an Alfa I know but another fine piece of Italian Machinery ) show that I have given blood sacrifice to the Italian Mechanical Deities.( henceforth known as the I.M.D. ) But .. engine mounts are to be done in spring so perhaps I will not assume the mantle of Alfisti until then so that the I.M.D. shall not smite me for my arrogance !! Have a great Christmas all !!!

 

[john.harrill]

I was able to remove the upper bellhousing and starter bolts of a friend's S4 with a series of long extensions and a wobbly joint. The gearbox and new clutch is back in.

My problem is getting to the the upper bolts to start the nuts!

Any suggestions?