how to replace clutch on 164 TS - Alfa Romeo Forum
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how to replace clutch on 164 TS

Hello folks

I have to replace clutch on alfa 164 (1991[H], 2.0 litre). Iwould
appreciate advise on how to do this as I have never done this before. I
am very new to alfa's, and I will be working without a manual. Or if
anyone has a manual I wonder if they could scan the pages and email it
to me.

BTW the symtoms are
1. there are various clunking noises from the bell housing gearbox area
when car is ticking over.
2.gears are vey difficult to select with the clutch depressed
3.when gear engaged I get a little drive then none then seems to act
normally for few seconds, then slips permanently and lots of smoke and
burnt clutch lining smell. is leaking sweet smelling oil (gearbox oil) so I think an oil seal must have gone.

This is on a car I bought for spares.... but seems far too good to
break. The previous owner told me he just had a new clutch fitted by
'MR CLUTCH' who contacted him whilst doing the job to tell him they
would not be able to garantee the job because the bellhousing was
contaminated............ I wonder if there might be a leaking oil seal
behind the fly wheel to the gearbox. It also feels as if there are
loose bits flying around in the bell housing ....... maybe a smashed
thrust bearing!!!

Any advise, info or manuals greatly appreciated and maybe I can save
this old alfa from the scrapyard.


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Re: how to replace clutch on 164 TS

Much depends on exactly what is wrong.

The Clutch can be replaced without removing the gearbox from the car. You unbolt it and move it 'out of the way' as best you can. Its tight, but thats how they do it, and it reduces the hours on the job considerably.Info supplied by my Alfa specialists.


Sounds like you have serious oil contamination which is either a failed seal or gearbox casing damage caused by broken components..either of which means gearbox out..which involves removing the wheelarch liners and the suspension leg and gearbox mounting, and its still very tight.

If I were faced with this decision I'd source a secondhand gearbox with good provenance and a guarantee of some kind (money back if faulty sort of thing) and do a swap, but you will need a clutch kit too.

Guess what...I've just had this job done on my 24Valve six weeks ago. I had a spare gearbox (as one does) and I was charged 360 to take the old box out and put the new in. My clutch was already quite new, and thankfully was not contaminated. In my case the pin between the planet wheels in the diff snapped and ground a hole in the gearbox casing...nasty!

I'm not complaining about the cost which I thought was very reasonable considering the hard work and grief involved!!

Let us know what you decide to do (or you could buy my TS off MOT, new front Discs, 72k on the clock, 92 pre-cat model)


164Super 24valve

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