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I do not weld. My last experience getting welding services did not go well and it required getting something welded in a relative position. So, found a complete assembly on eBay for $30 and hope it at least has a good spindle.
 
Are the bushings available separately, or is everyone getting the set and not using the new shaft? I need to rebuild the idler on my GTV and Spider.

Thanks,

Dick Stachowiak
71 GTV
71 Spider
 
This was a very useful thread. I just replaced my idler box with the ball bearing one from Classic Alfa. A few additional notes:

- Shaft came out from the old box and went into the new ball bearing box with just light tapping
- Steve is right that you can't really bend over the lock washer with the box installed. Unfortunately you also can't properly torque the nut on the arm with the box hanging free (Alfa specs 91-101 ft-lb!) What I did was install the box, then torque the nut from above, then drop the box again to bend over the lock washer
- Using the same washers/spacers as the original box there was a slight amount of vertical play in the shaft, and I know from past experience this'll cause noise. I added a thin nylon shim washer to take up the play
- My shaft looked quite good, but if you're using the ball bearing box you should probably be okay even with a reasonable amount of corrosion on the shaft. That's because the shaft surface is no longer a rotation point, it rotates on the bearings

All in all not a very difficult job.
 
This was a very useful thread. I just replaced my idler box with the ball bearing one from Classic Alfa. A few additional notes:

- Shaft came out from the old box and went into the new ball bearing box with just light tapping
- Steve is right that you can't really bend over the lock washer with the box installed. Unfortunately you also can't properly torque the nut on the arm with the box hanging free (Alfa specs 91-101 ft-lb!) What I did was install the box, then torque the nut from above, then drop the box again to bend over the lock washer
- Using the same washers/spacers as the original box there was a slight amount of vertical play in the shaft, and I know from past experience this'll cause noise. I added a thin nylon shim washer to take up the play
- My shaft looked quite good, but if you're using the ball bearing box you should probably be okay even with a reasonable amount of corrosion on the shaft. That's because the shaft surface is no longer a rotation point, it rotates on the bearings

All in all not a very difficult job.
If you tighten that nut to your torque spec you will strip it. Your torque spec is for the steering box pitman arm.

The idler nut torque spec is 18.5 to 23 ft pds.
 
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Huh. Well, it didn't strip, so that's good.

Where'd you find that spec? The S4 service manual only has one torque spec listed, and if it isn't for both arms then there isn't a separate one listed for the idler arm.

Anyway, I may have dodged a bullet...
 
Huh. Well, it didn't strip, so that's good.

Where'd you find that spec? .
The recall service bulletin were 500 pitman arms and idler arms had to be replaced on the 19991 models due to defects.

I did about 30 of them back in the day.
 
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Idler rebuild

My idler has lateral play so I ordered a Classicalfa rebuild kit.
Upon dismantling of the pitman arm I found out that my shaft has high corrosion (severely pitted on bottom).
Since the kit has a new shaft (I have not received it yet), how on earth is one supposed to replace it ? Does it screw/unscrew from the pitman arm... Some people mentioned welding. I dont believe people are actually going to do that so I assumed there is another way of dismantling it ?
Any body ever done that ?
 
My idler has lateral play so I ordered a Classicalfa rebuild kit.
Upon dismantling of the pitman arm I found out that my shaft has high corrosion (severely pitted on bottom).
Since the kit has a new shaft.......
.....Some people mentioned welding. I dont believe people are actually going to do that so I assumed there is another way of dismantling it ?
Any body ever done that ?
nope.
needs to be ground off and new one expertly welded back on in the exact (as in "exact"!) same position ....and that job is not for the amateur welder.

clean the shaft and post a photo here.

if you are certain the shaft cannot be cleaned up with emery, then perhaps try find a decent s/h arm or in fact a used complete steering idler....ebay has a few for around the 50 $ mark, some even say good to go, no play....or try APE for a good used arm

you will have to likely ream the bushes, and removing the bushes is also not easy either....

Overhauled complete idlers can be purchased, but they are not cheap (ca. 200 euros on exchange basis in Germany, for instance)
 
Idler rebuild

Thanks..
OK here is my shaft/pitman.
I guess I could live with it that way....

Or I can grind the weld off and have a local welder weld it...but it has to be very straight I assume or else I'll have issues...

Do you think my shaft is still good ... or toast ?
 

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Idler arm rebuild

OK I decided to bite the bullet and change the shaft....
I grinded the weld away... Hard to tel when I was at the shaft or not....
Then I put it in a 20ton press... and it would not budge... I heated it... hit it... pressed it some more thinking all the way that I had gotten myself into a bad situation and should of never started this !!!
Well after a last try and when I thought the press was going to break it finally got the shaft to move....
I cleaned it all up and pushed the new shaft in... Now I am not sure how far I should push it in.
I leveled the top should of the shaft with the idler aluminum body giving the extra room for the shims for tightening.*
Please let me know if I did this wrong.... I'll go weld all this tomorrow..
 

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Here is how far I pushed the shaft in. Is this the correct setting ?

Also anyone know where to get the rubber seal that sits between the idler body and pitman arm to seal the dirt out ?
 

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Here is how far I pushed the shaft in. Is this the correct setting ?

Also anyone know where to get the rubber seal that sits between the idler body and pitman arm to seal the dirt out ?
The first picture shows the shaft a little low with respect to the top of the housing. The second picture looks better. With the shaft and shim(s) installed and the nut tight (I don't recall a torque spec), I would adjust the shaft position to avoid noticeable end play and any binding. I bought the seal, in addition to the bushing and shaft kit, from Classic Alfa.
 
well you're brave that's for sure!
Did you not measure exactly the old shaft before grinding it off?

torque: on BB there are two differing torques for the idler nut, take your pick;)
1: 35-40 ft/lbs (member GTV-074)
2: 18.5 to 23 ft/lbs (member JimG who replaced a lot of idlers back in the day!)

see also this regarding end float and checking the arm turns in the new bushes (otherwise reaming necessary)
https://www.alfabb.com/bb/forums/874495-post6.html

have you tackled the bushings? you cannot just push them out because there is a lip in the housing....when I did mine they were absolute pita's!
I got a chisel to the end, bent it inwards all around, then hit it out from the other end using the lip I just formed....

seals:
https://www.italricambi.nl/index.ph...hp/component/virtuemart/stuurinrichting/stuurhuis-en-stuurstang/60547732-detail
 
No (spiderserie4) I did not measure the shaft extension before cutting it out.. I did not think of it (was too stressed about grinding the whole thing out).... Amateur mistake on my part !!
But I have the old shaft and the markings from the pitman arm so I can measure distances.
I am about right.

My issue is I can still change things. I understand I don't want end play - so shaft shoulder should not extend above the shim rings.
But I don't want it to bind !! So when I tighten the nut down I want the shaft shoulder to sit tight on the nut and ring.
Hard to make sure I get that one exactly right. I preferred to not have the should sit too close to the nut (avoid end play) and loosen the nut a bit in case it binds.
I'll get the bushings out tonight and set the new ones. Then I'll do a final set up to get the shaft distance right before welding.
 
OK I got the bushings out (a pain!)... and the new ones slide in and out by hand (not good ?).
I put everything together and checked the play by tightening. Obviously I had no play and when tightening the arm does not rotate anymore. So i went to the press and pushed the shaft out some more. Now I am almost aligned with the upper (last) shim. When i tighten hard the arm does not rotate but if I loosen it it does. I don't want to go any further because once the shims wear in I may lose some thickness and get end play....
Anybody have suggestions ? Should I push the shaft until even when the bolt is tightened the arm still moves ? What is my risk to get play later on and how does one correct that (adding shims I assume) ?

I also drilled a hole matching the bushing hole and set a grease nipple.
 

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Installing the bushings by hand is no problem.

You're never going to get it so that it doesn't develop play as it wears in. That's just part of the design and happened to new cars straight out of the factory. You don't adjust it as you go - just eventually rebuild/replace as you are doing now. It's just not designed to have absolute zero slop.

You might want to consider one of these if it's a concern to you:

https://classicalfa.com/su079-1-lhd-steering-idler-box-with-roller-bearings/
 
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