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High resistance connections in anything electrical appears to be about the most frequent cause of problems in our cars. Easy to deal with to make it reliable again but it take quite a bit of time.
 

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Discussion Starter #22
So got the starter working - didn't connect the power cable at battery end! Took a while of checking the connections at the starter before I realised!

So car is driving, clutch holds doesn't slip however it still isn't clearly, fully. First gear needs a bit of force to put in and reverse won't go until I turn the car off. The odd thing is it's better than if was before. I'm going to try bleed it again tomorrow on the off chance that fixes it.

Any ideas? When cars off all gears are good just when it's on its got resistance when engaging. Not too noticeable when driving through the gears
 

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So got the starter working - didn't connect the power cable at battery end! Took a while of checking the connections at the starter before I realised!

So car is driving, clutch holds doesn't slip however it still isn't clearly, fully. First gear needs a bit of force to put in and reverse won't go until I turn the car off. The odd thing is it's better than if was before. I'm going to try bleed it again tomorrow on the off chance that fixes it.

Any ideas? When cars off all gears are good just when it's on its got resistance when engaging. Not too noticeable when driving through the gears
Are you sure the friction plate isn't fitted back to front?

Also, what slave cylinder do you have fitted? It might well be that when it had the solid flywheel & clutch fitted, the slave was changed to a 156 V6 slave cylinder, which has a different bore to the 147 JTD slave cylinder. Buying a brand new genuine Alfa 147 JTD slave cylinder to rule it out as a possibility might be a good idea if you can't be sure your car is fitted with the right slave.
 

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Gearbox arm, slave cylinder and clutch bearing in these JTD-GTA gearbox is the same (except JTD 8v), so it shouldn't be problem.

Bleed it. If not work, then I think that problem is stage1 clutch.
 

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Follow the advice given. Hopefully it just needs a thorough bleed or slave cylinder. I hope it is not the clutch itself. That said, quite a few people seem to have issues when using this type of clutch. I always advise caution with an updated clutch as either the pedal will be heavier and more strain on hydraulics and release mechanism or simply the movement ratio in the cover plate is different and critical.

As said, hopefully you can sort it this weekend.
 

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Discussion Starter #26 (Edited)
Are you sure the friction plate isn't fitted back to front?

Also, what slave cylinder do you have fitted? It might well be that when it had the solid flywheel & clutch fitted, the slave was changed to a 156 V6 slave cylinder, which has a different bore to the 147 JTD slave cylinder. Buying a brand new genuine Alfa 147 JTD slave cylinder to rule it out as a possibility might be a good idea if you can't be sure your car is fitted with the right slave.
Yeah I triple checked this time about the rotation because I thought I'd done that the first time. Ah that's a good idea about the slave cylinder, I've yet to try putting a bar against the lever and trying it but I think I'd be best just getting the new slave cylinder...

Thanks again guys will get one ASAP!

On a side note I did a couple other bits which included changing both front abs sensors (again). The first replacement set were too long and broke when the cars wheels spun. Got another set from a different supplier and the same has happened! Even with washers I'll need to get some genuine abs sensors if I can find them
 

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There are two types of front wheel bearings and two types of front ABS sensors, looks like you've been supplied the wrong ones. By the sounds of it you need the short ones. I have one side in stock, genuine Bosch about £40, the other side I believe is orderable but I'd need to check.
 

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Discussion Starter #28
There are two types of front wheel bearings and two types of front ABS sensors, looks like you've been supplied the wrong ones. By the sounds of it you need the short ones. I have one side in stock, genuine Bosch about £40, the other side I believe is orderable but I'd need to check.
I'll definitely take the one you have in stock and if you could order the other one I'll take that too cheers
 

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I'll definitely take the one you have in stock and if you could order the other one I'll take that too cheers
Give me a call when you can, 01768 879171
 

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Discussion Starter #30
Just to update, new slave cylinder fitted and bled (genuine alfa) and the pedal feels great but still not clearing. I've came to the conclusion it is definitely not the hydraulics, unfortunately! 2nd, 3rd, 4th, 5th + 6th all engage with some force and a small crunch. 1st gear goes in but takes a fair bit more. Reverse will not engage.

I turned the car on. Removed the battery (car still running), battery tray and had someone in the car trying to engage gears and me watching the slave cylinder then swapped about. Now I placed a pry bar against the gearbox arm / actuator and had someone in the car try to engage gears. The arm was able to move slightly further than without the bar however the gears did not engage any easier. Reverse would still not engage at all. If I pushed the gearstick against reverse selector and turn the car off, the gear engages.

Hydraulics are good, gearbox was checked over by a specialist only thing left is the clutch... Really not sure where to go with this. Asked for a refund more than once but seller isn't offering one. I suspect its the 'pressure plate' not working correctly rather than the clutch plate? Anyone know where I could buy a uprated one on it's own which could work with the clutch plate? Or any other ideas what it could be, anythings worth a go.

Have attached a video / photo's of the gearbox arm being actuated with a pry bar not affecting gear selection.

 

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you need to have a matched pressure plate and a clutch disc

most probably you have a problem as you sad that the pressure plate is not releasing enough

or...

that the clutch disc is to thick and slightly engages the gearbox...

EDIT: if you suspect that is the problem, only buy a matched set that someone guarantees is good.
 
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