Alfa Romeo 5 speed hydraulic clutch transmission rebuild.
Don't want to do it yourself? [ Ссылка ]
Sorry for the noise in the background in the middle of the video, it goes away later.
Will post the final assembly soon and leave a link to it.
Key points:
Do not pry on surfaces. They are supposed to be machined to seal without any gaskets or RTV. Any damages will compromise the seal. I choose to use a little bit of RTV (red) when reassembling nevertheless.
Do keep notes and carefully detail where shims go. They will prevent sloppiness in the gearbox. The procedure to determine shims can be very time consuming and frustrating.
Catch the parts when you press them out!!!
Use the correct tools for the job. Once the bell housing is off, you will need 13mm wrench, 13mm socket, 12mm socket, 10mm socket, 32mm socket, mallet, flat head screwdriver (don't use it to pry housing apart), hydraulic press or gear puller, retaining ring tool, shop rags, mineral spirits (lacquer thinner), assembly grease/oil, zip ties.
00:50 - Removal of rear cover nut
2:18 - Removal of rear cover
4:15 - Removal of 5th gear selector
5:12 - Removal of selector shafts plunge
5:20 - M6 bolt, 10mm socket (correction)
6:20 - Removal of 5th gear selector shaft
7:05 - Splitting of case
7:43 - The right oil level mark is actually by the fill plug, you can see a thin line
8:06 - Brief explanation on how the transmission works
14:23 - Lightened gears 1 and 2
15:50 - Remove shafts from casa
17:26 - Explain selector rings exchangeability
18:05 - Remove shaft retaining ring for 3rd gear
18:53 - Press out 3rd gear -- Make sure to catch the parts!!
20:07 - Remove 5th gear and rear bearing
21:04 - Press out reverse gear
22:39 - Remove woodruff key
22:52 - Press out intermediate bearing
23:28 - Remove 1st gear
23:47 - Press out 2nd gear
25:57 - Replacing gears 2-5 synchromech
26:49 - Dog gears replacement
27:40 - Press out dog gears
28:19 - Gear 1 synchromech mechanism and dog gear
29:37 - Gears 2-5 synchromech mechanism "blow up"
30:54 - New synchromech
