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Discussion Starter #1 (Edited)
Hi everyone.
It is my turn to solve the dreaded M32 problems this car has.
The bright side is that I see that this gearbox has become well known and the fixes seem less scary than they there 5 years ago.

Problem is, we don't have workshops who specialize in those gearboxes specifically since they are not common in my country. As far as I know the Mito is the only car sold here with this gearbox (No Vauxhalls, no diesel 159,)
So my only options are taking the car to my alfa specialist,
or to a gearbox specialist for manual gearboxes.

A few questions for those who are familiar with the M32:

1. My alfa specialist is hesitant on doing the updated endcase and bearing job, he says if the orignal bearings are 55mm, he is not sure about the uprated ones being 62mm. He also says the newer endcase might not be compatible as a straight swap for my M32 gearbox on the Mito(afraid of it not fitting or taking up too much space becuase of different size). Can anyone shed some light?

2. As I said, we dont have workshops doing weekly M32 refurbs here as this gearbox isnt common. What we do have are people specializing in manual gearbox rebuilds. Should a gearbox specialist be able to do the job no problem, or does this M32 gearbox require some special experience and getting to know?

This is the kit I thought about ordering, but hesitating on pulling the trigger on the order. Can anyone confirm this is a straight swap on the mito fitting-wise?

https://www.ebay.com/itm/M32-Gearbo...517724&hash=item2aac8620d1:g:5jkAAOSwsYpaOPvx

I feel completly lost and have no one to get advice from. So any help would be lovely. thanks alot.
 

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Discussion Starter #2
Folks any piece of advice from people who did the M32 rebuild would be a amazing. thank you
 

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I'm not a gearbox specialist, but did do a bit of reading online when my M32 had a whine...

From looking at the photos of the newer end case it looks like the two extra oil galleries are the bits which change the profile of the end case to any significant degree (with the one to the main problem bearing being the bigger). This page has photos of each side-by-side:
https://www.eco-torque.co.uk/single...eed-To-Know-About-Uprated-Bearings-End-Casing

Courtenay also have a nice clear photo of the end of the later casing:
https://www.courtenaysport.co.uk/image/gearbox/M32-NewCase1_wwma.jpg
https://www.courtenaysport.co.uk/Gearbox-Rebuilds

WG Motorworks have mentioned that the revised end casing does seem to help with the so-called "6th gear" end casing bearing (as you'd hope), but that they still see issues with pitted pinion bearings (the diff-end ones on the output shaft)...
M32 Gearbox ? WG Motorworks

It was actually the diff-end bearings on my Mito which caused the whine on mine (the symptoms of that are a varies-with-road-speed whine which is there regardless of gear selection and clutch in or out, usually heard from 40mph up), although I think there was pitting on a couple of other bearings.

A couple of the theories of what leads to the problems (setting side oil circulation not being great around the 6th gear bearing) are over-shimming at the factory of some boxes so the load on the bearings is higher than it should be, so re-shimming as part of the rebuild (if the end casing isn't changed) is sensible. Courtenay mention incorrect shimming as do Helical:
M32 6 Speed vauxhall - Gearbox Problems

... and also that the gearbox tends to run too hot (mentioned on that Courtenay page) meaning the oil can go out of grade. I've read that using a better quality gear oil than OEM may be more resilient to the heat, and also having a gear oil change schedule (rather than treating it as "filled for life") can help.

You could try emailing WG Motorworks to see if they've ever done an end-casing upgrade on a Mito and whether there's space - I did email Warren with a couple of questions (he was the only one I'd seen use the term "pinion bearings" so checked with him if that was the diff-end ones) and he replied fairly quickly. You may find just looking under your car and seeing how much space there is around the area where that new oil gallery is could give you a feel for it! Alternatively if there's still no confidence in it fitting, I would say that just ensuring correct shimming on the rebuild and using a decent oil (e.g. Fuchs Titan Sintofluid, etc) and changing gear oil every 4-5 years should help reduce the risk of a repeat.

Can't help with whether there's anything special about the M32 in terms of a rebuild - would have thought it unlikely... It is a 3 shaft design (two output shafts). Some rebuild services in the UK who do a lot of the M32 (and at a cheaper price) do the bearing replacement in-situ (they take the end casing off rather than the whole box), but I'd imagine your specialists would want to remove the box!

There are exploded diagrams on the internet and maybe that would help give your gearbox specialist more of a feel for the box:
Autolusso - M32 6 Speed Gearbox

Video of one being opened on a bench and the shafts removed:

Quest in poland have a series of videos on M20 / M32 rebuild... All in polish obviously, but can see them working on the box... First episode here:

Rest are in their uploads:
https://www.youtube.com/channel/UClFCJotoBejYbBbYVvdyuZw/videos
 

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Another thought regarding finding out if there's anything special about rebuilding an M32 box - Adie at AlfaCare did the rebuild on my M32 and he's a fairly helpful chap so a quick email to him explaining the situation and that you'd just like to check if M32 rebuild is straightforward might get a reply:
Alfa Servicing | Quadrifoglio | Alfa Romeo Garage Hampshire | Fiat Abarth | AlfaCare

I doubt they've done an upgraded end-casing job, but no harm in asking too just in case
 

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Discussion Starter #5
Another thought regarding finding out if there's anything special about rebuilding an M32 box - Adie at AlfaCare did the rebuild on my M32 and he's a fairly helpful chap so a quick email to him explaining the situation and that you'd just like to check if M32 rebuild is straightforward might get a reply:
Alfa Servicing | Quadrifoglio | Alfa Romeo Garage Hampshire | Fiat Abarth | AlfaCare

I doubt they've done an upgraded end-casing job, but no harm in asking too just in case
Thank you Skaffen. I will keep looking into it. Hope the gearbox doesin't fail on me as I try to figure this all out...
 

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If the whine has only just started then hopefully failure is unlikely!

The risks, as I understand it, are basically that the amount of swarf (small bits of metal) that's come off in the wear has exceeded the capacity of the magnet inside the gearbox to collect it, so you still have swarf circulating accelerating wear. And also that a bearing race wears through to the point of breaking (not good!) or a roller is worn to the point of escaping the bearing cage (hopefully both are fairly unlikely if the whine has only recently appeared).
 

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When I had my Alfa 159 1.9 JTDM, the gearbox whine got louder and louder after a couple of years. Not deafening but a constant noise.

Upon taking the gearbox apart, we discovered all six mainshaft bearings were failing. We replaced the lot, stripped and cleaned the shaft and gearbox end case before refitting and filling with 3-litres of Fuchs Titan gear oil (yes, 3-litres). The gearbox was perfect after that. Sold the car some time later to a very happy customer. All this work was done by simply lowering the subframe and removing the gearbox end case with the actual gearbox housing still attached to the engine. This is obviously OK if you don't want to change the clutch/flywheel. My clutch/flywheel were both fine so it didn't warrant the extra work.

Either way, it's not a small job and not for the faint-hearted. Those in the know would probably not buy another Alfa with an M32 gearbox ever again. A real shame as the car was fabulously reliable apart from this major component fault. Guess we have GM to thank for that one!
 

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Discussion Starter #8
An update

Figured I would give a small update :rotate:

The noise in 5th and 6th is getting increasingly higher pitched, I find myself driving above 80kmh with either windows down or radio up.
3rd and 4th are pretty quite. I try to stay in 4th if I can.
2nd gear is also pretty noisy, no white pitch whirr but you can tell the bearing is suffering
(2nd gear has a slight background noise when getting off throttle, also you can hear a weird noise when engaging 2nd from 1st. I understand that 2nd gear is the same bearing as 5th and 6th so this makes sense.)

Surprisingly, gear changes are still smooth, and no jumping out of gear or wierd gear lever play.

Overall the car is noisy, not like it used to be. driving with windows up at night with no background noise you can tell somethings not right in the gearbox even though theres no high pitched whirr.

I ordered the new updated end-casing, new uprated 62mm bearings (instead of 55mm) and a full bearing replacment kit. ( just incase we open the box up and see other bearings failing)

My alfa specialist did a few 159 and classic alfa gearboxes in the past so fingers crossed everything will go well.

Will update.
 

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Discussion Starter #9
Success!

As promised I am updating this thread

I ordered the new end-casing and the bigger bearings. This is an upgrade that was introduced by Vauxhaull in 2012 due to the insuffiecient oil reach to the end-case bearings.





(photos are from the eco-torque UK website and do not belong to me)

Most theories say the original endcase bearings are shamefully too small,
The upgraded endcase allows the installation of bigger bearings, 62mm outer diamterer, instead of the old 55mm.
It also allows better oil flow the bearings as yoyu can see in the photos

Problem was, I couldnt find anyone who had done the endcase bearings on an Alfa, only on Vauxhaulls.
I took the plunge and ordered the whole end-case kit and hoped for the best.
The original bearing safety circlips are canceled to allow the bigger bearings to fit, and a set of shims is provided to counter this.

The job was done and all the bearings were replaced including front and back, and differential bearings.
My mechanic said the problematic 5th and 6th gear bearing was shot to the point of falling apart in his hand the minute he pulled it from the shaft!
the other bearings had alot of play in them and some had cuffing on the rollers.
The bigger bearings were fitted and everything went exactly as planned.

Car is silent now (not used to hearing tires and engine)
Also, gear changes are alot smoother, less notchy ( in a good way ),
2nd 3rd and 4th slide in alot more easily.

I see that this thread isnt getting much notice,
I just thought it could be helpful in the future for poor folks like me who live in countries that are not familiar with the dreaded m32 issues.
 

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Well done for persevering with the fix. I suppose in the UK it is a common problem, but with relatively easy fixes (ie lots of specialists who can repair it at moderate cost). As you say, very useful for those without those resources at their disposal.
 

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Discussion Starter #11
Well,
Turns out the wrong gearbox oil was put in the car.
I found this out because gearshifts are being extra notchy and sometimes crunching.
Did some digging and they put in the Tutela Technix (which is recommended for 5sp mitos) instead of the Tutela Matryx
Drove about 400 in a week and a half before I found out.
Went on and ordered 3 liters of Fuchs Titan Sintofluid, seems like this is the go-to oil for this box.
Lets hope I haven't damaged the new reconditioned gearbox in the meantime..
 

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Omryd, on the input shaft did you leave out the retaining screw/bolt? If bought the same kit but the bigger bearing in sticking half way out on the input shaft. If I screw in the retaining scew/bolt then the end case will not close.
 
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