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Alfa Romeo 159 2.4 JTDm TI Q4 transfer box

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4K views 37 replies 7 participants last post by  Intrigued 
#1 · (Edited)
My lovely rare diesel 159 Sportwagon TI Q4 transfer box has been badly damaged after I grounded the car. Once mounting kerb at speed to allow ambulance to pass and secondly transitioning between a tarmac road and an unmade one coming to an abrupt halt as caught the underside.

It is now making a horrendous metallic grinding noise as I accelerate and will go at some point soon even though it still drives and accelerates smoothly.

The transfer box is very expensive from Alfa so I am trying to source a used one.

Part number is 55560618 described as a 'Power take up'. Thanks to Alfa Workshop for the information. Very helpful chaps.

Apparently, it is a unique part to this 2.4 JTDM Q4 TI model and is NOT the same as the one used in the petrol 159 3.2 TI Q4.

Does anyone know of a used or new one in stock somewhere - I am hoping for a miracle otherwise I will have to write off my car and sell for spares and repair.

Alternatively, does anyone rebuild transfer boxes.

Maybe Ned at Autolusso can help?

Praying for a small miracle.

Thanks everyone!



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#5 ·
I have one! it came with a spare engine that I got for my car. complete with half-shaft.

2 problems though:

1- I am in Morocco

2- its heavy (can't possibly ship something like that through the mail...)


if you have a solution to said problems, I would be glad to help you.

i'll take a pic tomorrow at my shop and post it.
 
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#6 ·
Wow, thank for the quick reply! Just to be sure, is this one for the Q4 four wheel drive 159 diesel i.e. same part number. I note that you drive a 2.4 JTDM but it's not clear whether this is 4WD Q4.

Kind regards from a wet UK.

Raymond

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#7 ·
Sorry to hear you problems and I really hope you get fixed - there are too few of these cars around, I love mine!

I'm always checking eBay for spare part but this isn't something I've acquired yet however there was one for sale in Germany a few months ago, it's not listed at the moment but I think the seller was this guy who has a rear diff and cage list at the moment. It might be worth sending an email to him?

Alfa Romeo 159 2.4 MJtd Q4 Sportwagon Differential Hinterachse | eBay

Guy

PS - if this doesn't work out I'm sure Ned can sort it!
 
#10 ·
I've only seen the 3.2V6 version as mine lunched the output shaft bearing - lots of end float and side to side motion - I'd be surprised if it was a completely different unit, more likely the same unit with different change parts to fit it to the gearbox on the diesel - assuming the gearbox is different?

This is the unit fitted to mine:

Cars | 2-Stage Power Take-Off Unit - ZF Friedrichshafen AG

The rear diff is a standard ZF part too.

I contacted ZF for service information, ut was told (eventually) there is none. So I asked for build info, specifically the rolling torque required to set the bearing clearances on the output shaft, but they declined . . . grrrr.

It's a dead simple two stage gear reduction unit - nothing compared to the main gearbox. Comes apart easy enough - nothing in there to spring out and be lost. All bearings are standard, off the shelf. One seal isn't - the one that separates the main gearbox oil and the transfer box oil - there are ID numbers on it, but as mine looked fine, I left it. It does look ike you could use two separate ones if really needed.

If it is the output shaft (which would make sense as it probably got clouted), then you do need a new collapsible spacer, or shims. Or two sets of bearings to allow a solid spacer to be measured and made up - a decent gearbox rebuilder would know how. I reused the original, with addtional shims to allow me to collapse it a bit more, set to a rolling torque of 1Nm - thats quite low and you need a proper dial torque wrench to set it.

One thing - stop driving it now - you're filling the transfer box with metallic crap - which will wreck the other bearings in time, chew up the gears and make repair next to impossible.

My story is:

http://www.alfaowner.com/Forum/alfa...898-159-3-2-q4-transfer-box.html#post15147545
 
#11 ·
Thanks for all the useful information.

I have contacted New and will get his crew to rebuild my transfer box if a spare one can't be located. Will try the German eBay advertiser (thanks Guy!).

I have bought a cheap Grande Punto today as a runabout and have parked up my 159 Q4. Just need to arrange collection and delivery of the car to Ned now.

Many thanks to my fellow Alfisti - Save the Q4 campaign!!!


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#13 ·
Just because he says he doesn't ship to the UK doesn't mean he won't! He's listed the rear diff several times over the last 6 months so any sniff at a sale might change his mind. All he can say is no? If he does have one I'm sure that there's a way of getting someone to collect it for you?

Save the Q4!!

Guy
 
#14 ·
Will get in contact! Just for amusement, my temporary Grande Punto has an issue where opening the back doors (either side) from the outside require a light tap 3" below the handle and 3" back. Apparently a very common issue on this car - bizarre but it works!

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#24 · (Edited)
#34 ·
Just a quick note to express my thanks to Ned and team at Autolusso for sorting out my 159 Q4 Sportwagon.

I have driven it for c. 50 miles now and it is pulling beautifully, accelerating strongly and smoothly so that it feels like the car would have been when new. It's acceleration for a close to two tonne car is good fun and it is a real joy to drive. It no longer has any metallic grinding noises...It is eerily hushed in the cabin.

Thanks also to Bianco Autodevelopment who directed me to Autolusso after the original diagnosis.

All in all, it has saved my Q4 and avoided me having to write the car off.

Now my only issue is that the Grande Punto I bought has developed an electric steering issue just as I'm trying to sell it!




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#38 ·
Hi Ned, 'fraid the Grande Punto is not worth sending all the way to Bedfordshire from Kent but I'm sure it would be a good job. Will have to buy a remanufactured part and install myself on this occasion to avoid losing too much money on it. The things I have done for my Alfa! Even so, the Fiat has served me well for the 2,500 miles I've had it!

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