147 gearbox issues - Alfa Romeo Forum
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(Post Link) post #1 of 3 Old 07-01-15 Thread Starter
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Alfa Romeo 147

147 gearbox issues

Hey guys

Longtime lurker here, finally got around to posting but seeking some help . Im hoping someone can help me diagnose an issue im having with the gearbox on my 2001 Alfa Romeo 147 (1.6).

Basicly it just started yesterday when (coincidentally) I was driving in to get my MOT. The gearbox has always been a bit "loose" since i bought the car and 4th has been a tad sticky in the past. However as i was driving along i popped into third and my gearbox just popped out of gear again. I try to reingage and it ground a bit so i gave up and went to 4th.

Upon further testing i found that if 0 load is on the gearbox it will stay in third however if you apply the slightest accelerator or the engine goes close to idle (at about 20mph in 3rd) the gear will pop out and if you hold it in it will grind. I've got reletivly little experience with gear boxes but ive read that it could be either some rubber bushes which guide the selector in (an aparent easy fix), the syncromesh on 3rd gear (gear box out for a 500quid+ rebuild) or missing teeth on 3rd gear (again gearbox out for 500quid+ rebuild).

Anywho i recorded a video of me trying to pull the car away from stationary in each gear. All gears function and pull is felt except from 3rd which judders back into neutral and grinds when held.


Also before anybody says anything ive just completely stopped using 3rd gear since that grinding is sounds like its going to cause further damage to my box.
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Usually when the gear starts popping out the syncromesh is starting to wear on that gear.

You might get away with replacing the fluid for a little bit. But ultimately the gears are worn.
Unless there is significant movement in the engine mounts it shouldn't pop out of gear.

I've just watched the video and there is a fair amount of slack in the bushes looking at that gear stick. However mines been like that on all the boxes and gearboxes I've had (3 total) mainly because I've not replaced the top hat bushes. But none of the gearboxes drop out of gear.
I couldn't listen to the sound but generally grinding just shows how much wear on the sync there is.

Your options are :-

1) Remove gearbox, Strip down and replace worn parts = Expensive
2) Remove gearbox, Replace with reconditioned gearbox = Moderate cost
3) Remove gearbox, Replace with second hand gearbox = Cheapest
4) Live with it and avoid third = Free

When doing the above it maybe worth purchasing a new clutch and slave cylinder. Save on labour if you are paying for it.

Or do what I have done in the past if you can't be arsed.

Get a quote for a clutch from Mister clutch or other garages... They need to remove the gearbox to replace the clutch. When they refit the gearbox get them a replacement to fit. Avoiding more expensive labor.

Alfa 166 2.0 Twinnie - LPG and a few trick performance parts
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(Post Link) post #3 of 3 Old 08-01-15 Thread Starter
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Ah thanks. I was fearing it was something like that. A mate of mine just told me the exact same thing today. The car is coming up on its cambelt change aswell which is another 400quid. Looks like its going up to the auction "Sold as seen" imo will be much more financially viable for myself considering the cars only worth 700-800ish at this point in good nick.
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