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Dear Members,

I have a spare transmission for my '91 Spider that I would like to have rebuilt.

Can anyone recommend a shop that can do this work to a high level - and what particular items should be replaced as a matter of course when rebuilding this gearbox? I am willing to crate/ship this transmission to get it done right.

Thanks,

Aaron Pratt
[email protected]
 

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just had mine done (5 speed Hydraulic clutch) (but in the UK), bits to have done as a matter of coarse:
Syncro's
bearings

although the bearings could cost around $2-300. I had cooked mine, so had to.

Though you can buy a recon box with all this work done as an exchange, for the same or less than getting the work done to yours.
 

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Who did you use in the UK Jamie - and did you have the gears lightened? Any indications on £?
 

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Do you know the history of the transmission and how it was working when it was removed? If you're intent is to lighten gears, etc. that's going to be REAL expensive and unnecessary unless you're trying to build a box for competition.

Rebuilding Alfa boxes is not rocket science and could be carried out by any good gear shop as well as a competent owner/mechanic.

Items required for a minimum rebuild are (about $220):

3 Syncros (put on 1/2/3rd gears; 4th and 5th get minimal wear and should be ok)
1 Syncro Ring Gear (
New Front and Rear Seals

Assumes the following items are good (and usually are):

4th & 5th gear syncros
3rd/4th & Rev/5th gear ring gear sliders
All gears and gear bushings
All bearings
All shift forks

Synopsis:

1. New syncro rings installed on 1st, 2nd, and 3rd gears
2. New ring gear goes between 1st and 2nd
3. Ring gear between Rev and 5th is transferred to between 3rd and 4th and vice versa. (old Rev side faces 3rd gear since Rev is not syncronized and receives almost no wear. 5th gear also received almost no wear)

Here are a couple of web sources for rebuilds, although I can't vouch for their quality or extent of rebuild. Prices are usually around $800 exchange, although I've seen a company selling min rebuild transmissions on Ebay for about $350 exchange. Count on another $100 for crate materials and shipping.

http://www.paulspruell.com/parts/rebuilt_parts_and_equipment.htm

http://www.trailalfa.com/main.htm

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33733&item=2415459695

http://www.speedquest.com/gearlightning/ (Gear lightening)

You may contact a local clutch & gear transmission shop as well, if you don't want to do the work yourself. Alfa transmissions are very simple and require no special tools. I'll bet a good transmission man could do the work with the parts and spec sheet for clearance specifications provided by you.

I'm currently in the process of rebuilding my first Alfa transmission. After opening the case and checking clearances and general condition, it looks very good except for the normal wear items listed under the min rebuild parts list. It looks very easy. About the only special tools needed is a dial caliper, feeler gauges and a hydraulic press or large gear puller.

Since it's a spare, it'd probably be worth opening the case yourself and taking a look for obvious wear/damage. You can also check shift fork wear and feel bearings for roughness. At least that way, you'll know what you're up against as far as parts go.
 

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djone101 said:
Who did you use in the UK Jamie - and did you have the gears lightened? Any indications on £?
I used Richard Drake in Norwich (top bloke), Didn't lighten the gears as I use this for a daily driver in the summer - it's for posing not speeding (I use the 3 litre 75 for that).

cost me about £500 in total.
£300 labour
£200 parts
 

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I used Dean Russell at Trail Auto in Dearborn Michigan.
My second gear was starting to go (as usual). I had everything replaced b/c I didn't want to mess with it for a while. I think it was about $800.TRAIL ALFA
 

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Does anyone know what "gear lightening" entails?
I would like to do this when I rebuild my transmission this winter if it recommended.
I do drive my car daily,
(I have a Hyundai Elantra GT when "olio" needs a "break") -
What effects does gear lightening have on driveability? will it weaken the gears?

I have access to a professional machine shop - I just have to tell them what to do with the gears when I bring them in (if?).

I'll definitely put in a new clutch kit as well - LineaRossaUSA has the 3pc kit for only $150.

Vlad at LineaRossa is great - I got 4 new Koni Red's for $300 INCLUDING FREIGHT in January.
Spider corners on RAILS now!!!
 

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I don't have lightened gears in my Alfa, but other say it works very well to help fast shifting and prolong the life of the syncros. I don't work my gearbox like a race car, so I really don't see need.

I don't know how practical it is to do it yourself, unless you're a qualified machinist. The gears themselves are very robust, so removing metal, I don't think, has weakens them that much. It's a question of how much to remove and where, and also the very important aspect of making sure the gear is balanced.

See the speedquest link in my above post for pictures of lightened gears.
 

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The Alfa Wicki (what a strange word!)
There's so much good info out there and all so scattered about.

It seems to me that lightening the gears is overkill for a street car, it sure would be interesting to shift like mad and never have to think about synchros grinding!
 

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I don't think anything is too much for a street machine.

If it allows you to shift like a mad non-gear-grinding hellion - or at least get you closer to that goal - then it's worth it.

I probably shift just as much as any autocrosser - it just takes me all week to accumulate the shifts that a racer gets on Saturday. :p

Seriously though - is there any info out there on the exact weight reduction, process, dimensions - ie. "take 5mm of each side of 1st, drill 8 holes and balance by shaving here..."
 
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