Re: Gearbox replacement DIY
Its well worth going for a replacement box instead of rebuilding yours. 90% of the broken gearboxes I've seen have been recon boxes supplied by Alfa. I think its because they cannot be re-manufactured to a fine enough tolorance. So I would therefore avaoid a gearbox rebuild. Its expensive, time consuming and probably not very reliable in the long term.
I think its probably possible to do it without removing the subframe, but removal of the subframe is the recommended method. - I've replaced 6 or 7 gearboxes on 156's and in each case I've taken it off.
If you search for my ARB replacement guide you'll find instructions for removal.
You don't need to dismantle the o/s front suspension but it will makes things easier. Lining up the mid shaft (that runs along the back of the engine to the o/s) AND the input shaft to the gearbox with the clutch at the same time is particularly awkward.
If you undo the hub nut on the n/s and remove the lower arm you can slide the upright off the drive shaft. You then just slide the n/s drive shaft out of the box.
The clutch slave cylinder is boted into the gearbox bell housing. If you replace it (worth it if you've not replaced it with the clutch) remember to remove the nylon packing piece that looks like its part of the new unit...
Last edited by Chris155; 11-04-08 at 15:20.