COVID-19 Coronavirus Message Updated: 8th July
Mail Order Customers:
  *
Our carrier DHL is operating near normally across the world. Allow an extra day for delivery (2 days for Australia, 6 days for New Zealand), just in case. However, regular international postal services can have additional delays, and are not recommended for anything required within 6 weeks.
  * For the UK only, Royal Mail are delivering the vast majority of orders on time according to our data, but is experiencing higher levels of staff absences, so there may some local delays.
  * We will be working normally and have a large warehouse full of parts that will help keep your car on the road. However, we are beginning to see supply delays from factory lockdowns around the world.
Workshop Customers:
  *
Following government guidance, we are open as usual. Taking your vehicle to a garage for repairs is a permitted activity (safety) as long as you observe the social distancing rules. We have strict social distancing processes internally and disinfect daily (not least because we have staff in vulnerable groups). In the circumstances, we have had to close our waiting room. Our mechanics wear gloves at all times and we will disinfect your vehicle with our Zaflora sprays on handing back to you. We would respectfully ask you to show our staff the same courtesy. We also have full amount contactless payment systems.
  * MOTs due for renewal from 30th March to 31st July will be extended for six months. However, you are still legally obliged to keep your vehicle in a safe and roadworthy condition, so if you need to use your car in this period, it is still strongly recommended to get one done.







This page:

How To.. Strip and rebuild an Alfa Romeo Giulia Gearbox

The 105 series Giulia has a really nice aluminium gearbox that is interesting to strip down; it is a constant mesh gear box and has baulk rings instead of syncros.

The most common cause of trouble with this gear box is crunchy second and third gears caused by worn baulk rings. In order to replace the rings you need to remove the main and input shafts, this is a quick insight into how to do this.

:alt

The first thing to do is put the gear box on a nice clean bench with plenty of room so you can lay things out in order, then it is best to remove the reverse light cable from the outside of the gearbox.

:alt

The bell housing can then be removed by undoing the 17 mm nuts inside it. Once these have been removed, a sharp tap will unstick the bell housing from the body of the gearbox.

:alt

Next we turn our attention to the rear of the box and we remove the drive flange nut and then pull the flange off, the gear lever stub now needs to be removed.This is done by undoing the two breathers either side of it and then prizing the domed cover off. Under this you find a plate with the device that stops you going from 5th into reverse this also has to be removed.

:alt

You are now free to undo the rear case of the gear box, this will also need a sharp tap to unstick it.

:alt

Once this is removed you expose 5th and reverse gear 5th being the gear furthest to the back.

:alt

Now we have to separate the two remaining halves of the gear box, before we do this we need to remove the 5th /reverse selector fork as it stops the two halves separating, this is done by removing the 11 mm bolt that secures it and pulling the shaft backwards. The two halves of the box can now be split and the shafts simply pull out,

:alt

...next you have to strip the shafts down!

Related Links: Alfa Romeo Twin Cam Engine '54-'97 | Alfa Giulia Engine Strip | History of the Alfa Romeo Badge | Alfa Romeo Model Identification | Alfa Romeo Giulia Gearbox strip and rebuild

Contact Us | General Interest | Alfa Insurance| New Alfa Romeos | Club Corner | Terms & Conditions | © Jamie Porter Ltd