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Problem shifting gears

2K views 16 replies 7 participants last post by  NineOneSix 
G
#1 ·
Hi all!

My '97 155 TS has all of a sudden become very difficult to shift gears. I really have to use force to get them in. This happened during a longer trip without any warning with bad noise or anything. If I turn the engine off the gears fall into position just fine, therefor I exclude any problems with the shift-linkage?. I have checked the 'clutch-pump' and slavecylinder for any visible leaks. I also measured the 'clutch-arm' and it seems to move alright (17,4mm according to workshop manual).

Would appreciate any ideas about this before I try to locate an alfaworkshop.

/Marcus
 
G
#2 ·
Maybe sounds too obvious, but did you check your oil level in your gearbox?
It could also mean your clutch is warped or damaged. That way it would not
become totally free without the hydrolics being at fault.
 
#3 ·
macahan said:
Hi all!

My '97 155 TS has all of a sudden become very difficult to shift gears. I really have to use force to get them in. This happened during a longer trip without any warning with bad noise or anything. If I turn the engine off the gears fall into position just fine, therefor I exclude any problems with the shift-linkage?. I have checked the 'clutch-pump' and slavecylinder for any visible leaks. I also measured the 'clutch-arm' and it seems to move alright (17,4mm according to workshop manual).

Would appreciate any ideas about this before I try to locate an alfaworkshop.

/Marcus
Happened to me....no noise but the thrust bearing was seized and was wearing through the diaphram....it eventually wore right through and no clutch.
 
#6 ·
Top up the brake fluid reservoir and then bleed the clutch. I think you may have a small fluid leak at the clutch slave cylinder, or even a porous hose between the reservoir and the clutch master cylinder.
Don't force the gears- a box rebuild is expensive.
You'd be better using light pressure on the gearstick, and then trying to match engine speed to roadspeed for the gear you're trying to find- then it will just drop into gear with no noise or effort, and best of all, no damage.

I'd expect labour to be 5-6 hours for a clutch job on the 155- but I've not done one yet-120k and counting :p
 
#7 ·
This has just happened on my 97 ts..my mrs nicked it off me to go to work on fri..sitting at a jnctn and alas would not go into gear..shift has been knotchy for a while..I havent had a chance to see for myself as my old company i worked for (recovery co) picked it up and i havent seen it since!! going to pick it up tonight as they say its working again?? (after they quoted me £350 to do the clutch)..(mr clutch charges £303) will check out for leaks ect when home..Hope i dont have to fork out 303 squid!!.
 
#8 ·
A stiff change (even when the engine isn't running) that gets easier when the engine is warm, is likely to be sticking linkages. There are about 4 or 5 ball-jointed connectors in the linkage and they dry out and seize up a bit (they're metal in a plastic cup). Give them a squirt of spray grease and they will come up all nice and loose.


Ralf S.
 
#10 ·
Yoinks! Gearboxes are a bugger because the parts seem to cost £40 each and you only need 4 or 5 plus a bit of labour before the cost racks up.

Yours does sound like the synchro' but if the menders find other bits worn out, then it may quickly get to the point where a recon'd 'box is the more cost-effective solution.

Alternatively, you may be able to find a second-hand 'box from a breaker (the 1.8 is fairly common and possibly other Fiat/Alfas may use the same 'box) but obviously that would be an unknown quantity.

Ralf S.
 
#13 ·
Hang on..... do the gears crunch when you have difficulty shifting. If they crunch then it points to the clutch - mechanical or hydraulic problem. Otherwise, the problem would likely be with the linkage, as someone mentioned earlier, possible partial seizure.
 
#15 ·
Well if it crunches on only one gear it may be the case of a slightly weak synchro ring, for the 2nd gear in your case. If you can 'beat' the gearbox into 2nd gear on the upshift and downshift, you may be able to carry on with the same box for thousands more miles yet. :)
 
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