Uprated 2nd Gear Synchro 68 GTV

The stock Alfa gears are heavy and wear the synchros early. The usual cure is to have the gear machined/lightened. Many thread already on this. Do a search and you'll find lots of info. I'm not aware of any "uprated" synchros.

Yes, you can remove the transmission without removing the engine. It's not impossible, but pretty darn close. Most people remove engine and trans at the same time. Actually, most of us just live with the lousy syncro and just shift s l o w e r....
Good luck!
Mike

Thanks Guys

It looked possible from underneath the car but I think I may as well invest in a hoist.

I am quite concerned that a 75 conversion may mean that I will replacing the synchro on a regular basis

- Jim

Jim,
I am fan of taking out the gearbox on its own, without taking out the engine.
The only tricky part is undoing the gearbox to engine 13mm nuts, at the top near the transmission tunnel.
I find this to be a tricky, but not impossible.
Take out the driveshaft, gearbox mount, reversing wires, stick your jack underneath the gearbox, (I use a tie-down to attach the gearbox to the jack)and pull.
NB - If you don't use the tie-down or rope to attach the gearbox to the jack, it could fall on top of you!!
Good Luck
Ian
1750 GTV's.

kiwi-kid said:

Jim,
I am fan of taking out the gearbox on its own, without taking out the engine.
The only tricky part is undoing the gearbox to engine 13mm nuts, at the top near the transmission tunnel.
I find this to be a tricky, but not impossible.
Take out the driveshaft, gearbox mount, reversing wires, stick your jack underneath the gearbox, (I use a tie-down to attach the gearbox to the jack)and pull.
NB - If you don't use the tie-down or rope to attach the gearbox to the jack, it could fall on top of you!!
Good Luck
Ian
1750 GTV's.

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I agree that it's easy to remove the gearbox. (This also makes it much easier to remove the motor if you are working without a lift.)

IMHO, it's easier to just slide the 'box out and let it reast on your chest. Alfa gearboxes don't weigh very much and someone of average upper body strength can easily support the 'box. The trick is to use tall jack stands which give you enough room to work comfortably under the car. Once everything is loose (don't forget the shift lever) , the gearbox comes out very easily. Support it on your chest and then slide out from under the car or set the 'box on the floor and you're done.

Thanks Guys. I am starting to feel brave enough to give it a go over the winter.

- Jim

I bought a transmission jack (less than $100) and now I wonder how I did without for so long.

Its not so hard to pull the box from below, just take your time as you only want to do it once every 10yrs or so!

John is right. The transmission jack is especially handy for re-installing the tranny.

A few more hints: tilt the engine backwards by lifting under the front of the oil pan. This makes it much easier to slide the transmission backward. And, if you decide to replace the clutch "while you're in there", don't forget to buy a clutch alignment tool. IAP has a cheap one molded from plastic, or use a spare transmission main shaft if you have one laying around. Oh yeah, don't pull on the plastic alignment shaft to move the engine (as me how I know).

john.harrill said:

I bought a transmission jack (less than $100) and now I wonder how I did without for so long.

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No biggee at all to get the trans out the bottom without removing the engine. Get the car as high as possible, use a trans jack, remove the exhaust and driveshaft, and tilt/jack the engine so the front is high and rear is low. Should be a morning's work to get it out.

Andrew

You've probably thought of this allready but once you've got the tranny apart I'd change more than just the 2nd gear syncro ring. I'm doing 1 through 4 plus two sliders/sleaves since it'll be right there. I'm considering lightening my 2nd gear but it is real pricey.