Re: 166 6-Speed 5th / 6th Selection Problem
Sorry been occupied with other things of late - houses!! Sounds like the bushes problem. The bushes are a plastic material and very thin, I would guess half a mil or so. They are fitted in an alloy casting with the steel shaft of the bellcrank type lever passing through. When the lubrication has gone the alloy casting starts to corrode, expands and squeezes the plastic bushes tight into the shaft. the whole lot then starts to seize resulting in the gearlever becoming stiff across the gate. In the long term the bushes will wear out and the whole thing becomes sloppy! Easy solution is to remove the assembly take out the shaft and knock the bushes out. The drilling in the casting can then be cleaned up - a small rotary wire brush is good, clean and lubricate the bushes and its usually perfect again. I think new bushes are available if necessary. Almost all modern Alfas use the same system and suffer the same problem despite differences in gearboxes _ I've just done my son's 147, different box but the same problem and I think identical bushes.