[Gordon Raymond]

Don, have more than one beer. The adjustment screw had a jam nut that locked it into position on the top aluminum cover. The cover was threaded.(have another beer) It acted on the top of the shaft to keep it from moving up and down. Usually, the steering wheel centered has the most play. The adjustment is TOO TIGHT if there is any binding at the ends of steering wheel rotation (lock). This is most easily checked with the front wheels off the ground. Tie rod ends are a common source of slop on the front suspension of the 101 cars. If the threads in the top cover are gone ( ), someone has applied a lot of torque to strip them out! If the lock nut is gone ( ), thats not good either. (have another beer) I believe the top could be repaired, but it might be easier to find a used top (or 101 parts box). From your discription, none of this sounds too good due to the possibility of metal in the steering box. (one more beer!) Keep us informed.
Best, Gordon Raymond

 

[Gordon Raymond]

Hi Don,
Let me ponder this a moment. Meanwhile, contact Alfar7 here with a PM. Richard Jemison. He is as good (BETTER) a fabricator of the "not longer existant" as I, a great machinist, and the ultimate Alfa performance "fixer". I am sure he or I can come up with a simple and inexpensive fix. Did you compare the top covers before replacement? It is possible the damage was done by incorrectly shimming the bottom. This may still be repairable in the car. Get a note off to Richard ASAP and have him look at this thread and give an opinion. Meanwhile I'll look at one apart tonight. Best, Gordon Raymond

 

[Gordon Raymond]

Back again. I've seen one where the cover was removed, and the shaft lifted enough to 'loose" one of the balls. It actually jammed somewhere, not allowing the sector to drop fully down. Boy, this was 40 years ago. (?) I remember it came to me like that for reassembly with the top off, and after fooling with it awile, it all went back together correctly. Something is holding your sector up. I'll think some more. Best, Gordon Raymond

 

[Gordon Raymond]

World's fastest ZF gearbox rebuild (less R&R)

WoW Richard! You are FAST! I was just looking at mine, and yours is DONE!
Checking the parts list, these internal box parts are the same #'s between the SS and Giulia spider, so the rebuild should be the same. With your pictures, Don should be able to R&R his SS box without problems. With his spare parts set up, he should have plenty of spares and workable parts. Your discussion of the proper relationshop of the keyway and parts should easily enable Don to get his back together, working
properly. Thanks, as always, for the education! Best, Gordon Raymond

 

[Gordon Raymond]

You are correct Stewart, but with Don's unit, it seems incorrectly assembled as Richard mentions in his 1:35 PM post. His paragraph two of that post discusses the critical relationship between the roller and the SHORTEST point on the worm. Any other assembly will make the roller assembly too tall to get the top on. It will work, somewhat, but the internal relationship between worm and roller are incorrect. Richard, tightening the thing down as far as possible, shows the available LIMIT of adjustment. As he later mentions, loosening it up, prevents the binding at the extremes you mention, while still allowing the center "play" necessary to keep the roller from pounding flat spots on the worm. The central play then, seems designed in to prevent hammering the worm and roller, though as you mention, over time and much vibration some wear can probably be expected. Not being an engineer, most of this is opinion, though the early Ferrari units are a similar design, and after actually breaking one of thoseeek in an accident, I have learned that not only proper assembly and lubrication are necessary, but correct adjustment as well!
As far as measurable wear, the only things I have ever seen are normal wear on the roller, which can be seen in Richards photos, or flat spots on the screw from a bash,( I have a 275GTB part that looks like that!) or incorrect adjustment. These served Alfa well for many years. Best, Gordon Raymond

 

[Gordon Raymond]

If you consider the function, if the system is tight in the middle where most wear is common, it will be dangerously tight at either extreme, full lock in either direction. Generally, you adjust the sustem (BOTH front wheels off the ground) for firm contact at turning extremes. If it has too much play in the center, it's time to begin replacing components from my experience.

 

[Gordon Raymond]

Happens to me every day Ken. Don't know why....