Dismantle Alfa 156 Gearbox

Started by jayarr, March 12, 2019, 09:58:15 PM

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jayarr

Hi all,

we have a manual 2003 156 JTS 2.0L, which which has been taken off the road due to some worrying noises in the gearbox. The end cover was taken off, and a couple of gear teeth were found in the oil. Subsequently the gear box was removed and have verified that at least some of the teeth were from the differential ring. At this point unable to separate the sections of the gearbox more than 10mm.

Any tips on how to dismantle the gearbox?  Do the staked on nuts on the driven and output shafts need to be removed first?

Any help appreciated!
Mito QV, Fiat 850 Sport, Alfetta GTV 2L
Past life: 33 1.5L, Fiat X1/9,75 V6 2.5L, GTV V6 3L 1998, 156 JTS 2L 2003

Craig_m67

Might be cheaper (faster) just to replace it with one from a wrecker....
'66 Duetto (lacework of doom)
'73 1600 GT Junior (ensconced)
'03 156 1.9JTD Sportwagon (daily driver)

bazzbazz

Craig may be right, one has to remember that there could be more damage elsewhere, especially after having shrapnel flying around inside.  :-\
On The Spot Alfa
Mobile Alfa Romeo Diagnostic/Repair/Maintenance/Service
Brisbane/Gold Coast
0405721613
onthespotalfa@iinet.net.au

jayarr

Quote from: bazzbazz on March 12, 2019, 10:28:31 PM
Craig may be right, one has to remember that there could be more damage elsewhere, especially after having shrapnel flying around inside.  :-\

...With little in the way of guarantee that the replacement gearbox does not have the same issue, or worn synchro's and bearings. I reckon, a least have a bash at opening it up for a look. Might even learn something!

Gearbox on the healing bench.
Mito QV, Fiat 850 Sport, Alfetta GTV 2L
Past life: 33 1.5L, Fiat X1/9,75 V6 2.5L, GTV V6 3L 1998, 156 JTS 2L 2003