Alfa Romeo Forum banner

GT 3.2 gearbox rebuild

10K views 17 replies 9 participants last post by  Rachelba 
#1 ·


The gearbox in my GT is nearing its end, it sometimes whines in first / second gear and when cold I have a hard time getting it in gear. I've tracked a spare 166 3.2 box that's in my garage as we speak. I want to have that box rebuild, put in a Quaife an swap it with the box on my car.

My question is, can I do the rebuild myself or do I take it to a specialist? Do I need any special tools to work on the gearbox?

Sent from my Nexus 5 using Tapatalk
 
See less See more
1
#6 ·
Just read the entire thread and as far is I can see just swap the diff house and dipstick.

Any thoughts on opening the box for inspection / rebuild or leave it up to the specialists? Any special tools required for opening and closing the box?

Sent from my Nexus 5 using Tapatalk
 
#7 ·
There's not a lot inside that you can check or repair;

Alfa Romeo forum: V6 Gearbox stripdown (56k)

I didn't get much help when I posted up pics of the 147's gearbox internals either, and that was broken...

So....

The gear box has some positives and some negatives. It has a Q2 :) but it whines in 2nd gear :( and jumps out of reverse gear:censored::furious:....

So I started to strip it down not really knowing what I am doing;

IMG_7031 by Chris 155, on Flickr

IMG_7032 by Chris 155, on Flickr

IMG_7035 by Chris 155, on Flickr

Top hat housing removed...

IMG_7040 by Chris 155, on Flickr

So this is reverse gear...

IMG_7047 by Chris 155, on Flickr

The bolt in the top of the shaft goes through the gear box casing into the shaft, I've just popped it back in for safe keeping... But it does mean that the shaft's position in the box is 'fixed'.

IMG_7050 by Chris 155, on Flickr

IMG_7055 by Chris 155, on Flickr

And this is 2nd gear. The box has been rebuilt following the expiration of the standard diff, I suspect that the marks on the gears will be as a result of this but could this be the cause of the whine it has in 2nd only?

IMG_7068 by Chris 155, on Flickr


IMG_7072 by Chris 155, on Flickr

IMG_7074-2 by Chris 155, on Flickr

Back to reverse. If you move the selector ring to engage reverse, it doesn't lock into position like the other gears do. I don't really understand how it is supposed to work as the other gears use a different mechanism (3 roller bearings with springs behind them that lock into a groove on the inside of the gear).

This is it in it's disengaged state

IMG_7077 by Chris 155, on Flickr

And engaged...

IMG_7076 by Chris 155, on Flickr

There's not really anything to it and I can't see anything missing relative to what's on elearn.

IMG_7078 by Chris 155, on Flickr

IMG_7079 by Chris 155, on Flickr

IMG_7080 by Chris 155, on Flickr

But if you prod at it in its disengaged state in the open box there is significant movement in the deeper (thicker) top cog, like something is amiss. (see video below) There is a point where I think the two parts will hold the top cog in a correct position and not allow it to rattle around whilst still not being engaged but I can't see how this would be achieved. There doesn't appear to be any means of adjustment.

Pic below is of of the 2 main shafts in the box, reverse operates as a 3rd gear between the two so that, obviously, one the output shaft turns in the opposite direction...

The shaft at the top of the pic is the input shaft and the one below it is the output. The pinion gear for the crown wheel on the diff is on the thick one on the very left of the output shaft.

IMG_7082-2 by Chris 155, on Flickr

IMG_7083 by Chris 155, on Flickr

It's got me beat.:irked: Help?:paranoid:
 
#14 ·
Swapping the diff-house was no problem. Got a 2 year warranty on the job. Q2 is a blast to drive, did not know what to expect but well worth the upgrade. Original diff was worn and needed replacement anyway. Picture is the revised box still with the 166 house.
 

Attachments

#15 ·
The Q2 makes a huge difference to the traction of the car as you have found.
If you're going for a really spirited drive turn off the ASR (traction control) as it's quite intrusive in it's set up and can kick in before you get the optimum performance from the Q2.
 
#16 ·
After a few weeks the car is back in the workshop. Changing gears when driving is fine, but once you put in in neutral and try to get back into any gear it takes quite some force to get it in. It seems the clutch is not fully disengaging when you press down the clutch pedal. When putting the car on a very slight incline it starts to roll when in neutral, if you put it in gear with the clutch pedal fully pressed it stops. As I supplied the clutch myself I'm afraid it's going to be an expensive fix. Clutch was a new VALEO boxed and sealed.
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top