Here the Gearbox had been removed, showing the state of the rear main and its clearly the source of my oil leak

 

 

Phone close up

 

Clutches/Flywheels!, SMF from a 3.2 GTA (top left), a worn out DMF (top centre), Worn Clutch Friction disc (Top Right) New Pressure Plate and release bearing(bottom left), very burnt up old Pressure plate (Bottom Centre), New Friction disc bottom Right.

 

 

A bad photo from my phone of the old friction plate, the rivet was very close to the surface, i doubt it would have lasted long with my planned usage. the outer edges were also bald with no grooves on. 

 

DMF Clutch and SMF Clutch

 

 

New Clutch fitted and Aligned. Note the lack of the Release bearing as it was fitted to the release fork and input shaft to the gear box. Then clicked in one the gearbox was fitted.

 

 

Then once mated, it was lifted back up, to be moved around, then put back into the car

 

 

Then the final shot. The Engine home once again.

 

 

All in all, it has been an experience. Time constraints caused me to be very stressed at times, and did take a lot of the fun and enjoyment out of it when things went wrong. That was simply because i didnt have the space to do it at home, which introduced a london daily commute, and working within fixed hours as the building had to be locked up. 

 

But none the less when things were going smoothly i loved it. The most enjoyable moments were:

 

1) checking the Cam timing after turning it over 10 times to find it was spot on

2) Getting the gearbox mated, clicking the release bearing in, followed by a heath robinson test of the clutch (in gear, turn both drive shafts, have someone with a pole operate the clutch)

 

 

Most nervous

1) Starting the car and not having it explode

 

 

However that soon ran out as i was left with this to deal with tonight, along with a rounded wishbone nut, and 3 rounded brake line couplings (found them like it Grrrr)

 

 

 

Finally just like to add, Big thanks to Richard couldnt have done it otherwise and also being able to take decent pictures, unlike me who is crap with a camera, and crap at standing still much to Richards annoyance hahaha

Great write up Taylor. A true labour of love owning an Alfa. Sorry to see another niggle show itself. Fair play for sticking with it though. Will be like a new car once your done. Can you replace the brake lines with braided ones?

Thanks Charlie

 

The Brake lines are Solid from the ABS pump to the Chassis Leg, then from there to the bottom of the Suspension strut is a braided line, followed by a short metal line to the caliper. Ideally ill have that short one replaced and ill grind the bolt off of the Caliper (being careful not to put too much heat into it as its aluminium afterall) then drill it out and maybe run a tap through it. Luckily with the disc off of the hub, its easy to get to the wishbone nut n bolt, so ill grind that off and buy a new nut and bolt.

 

In all honesty, the latest problems are all very easy to fix, but the its timing. I was trying to fix little niggles left from the past weeks worth of work, but i cant do that now as i need to drive it to see if the exhaust heat shield is still vibrating etc.

Got there in the end. Slightly pushed for time Friday night!!!

Very well done and impressive Taylor! That was indeed a labour of love.. or you're one sick masochist!?!

 

Brilliant write up and excellent photos, kudos Richard, to explain to us mere mortals everything you did.

 

Hmmm an Alfa... shall I buy an Alfa now someone actually wants to work on them......

Wow, that's a lot of work! Great stuff and read

Excellent project, great write up and images, well done.

Thanks Chaps.

 

Towards the end it was becoming tough. But danny stepped in and helped get it ready to go.

 

I am taking the caliper to work tomorrow and after work ill drill out that sheared bolt and run a tap through it. Hopefully that will be fine.

 

I collected the Angle grinder from my mums garage to cut off the lower ball joint nut, a new one will be ordered tomorrow. 

 

 

So Now I just need to find a 11mm Flared brake line spanner so i can get the short metal brake line off, have a new one made up (Mike, do you reckon Snodhurst could make me one up?) then put it all back together and bleed the brakes (new Brake fluid to be bought too :( )

Thanks Chaps.

 

Towards the end it was becoming tough. But danny stepped in and helped get it ready to go.

 

I am taking the caliper to work tomorrow and after work ill drill out that sheared bolt and run a tap through it. Hopefully that will be fine.

 

I collected the Angle grinder from my mums garage to cut off the lower ball joint nut, a new one will be ordered tomorrow. 

 

 

So Now I just need to find a 11mm Flared brake line spanner so i can get the short metal brake line off, have a new one made up (Mike, do you reckon Snodhurst could make me one up?) then put it all back together and bleed the brakes (new Brake fluid to be bought too :( )

 

I'm sure Jay or Chris would help you out, though if you fancy making one up yourself I've a couple of different types of flaring tools, might have a bit of copper pipe somewhere as well. I don't think I've any fittings though. If you want to pop round I'll throw you a few bits and a spanner so you can have a go yourself I'll show you how to use the flaring tools its not that difficult.

After all this work, I hope it makes it to Combe.

Lunch time well spent!

Drilled out the caliper bolt and sent a tap through it.

I would helicoil it but i dont have access to an M12 Helicoil kit.

i would add a photo but im on my phone and i can't paste in my photobucket link

http://i264.photobucket.com/albums/ii191/Warlord_1011/Cars/Alfa%20GTV%20T530%20BFC/20150420_123841_zpsiog65x9q.jpg

Just need to buy a new bolt and then sort the brake line out.

Slight change of plan. I questioned my work and took it to the on site machine shop.

They had a look and suggested that I have a steel insert fitted. As i dont have an M16 tap or a drill capable of holding a 14.4mm drill bit. I have left it with them

Went to Snodhurst Garage, 10 minutes later i walked out with a replacement brake line  

 

I accidentally said what it was for, and the guy said "£10 please, Certainly cheaper than buying one from Alfa Romeo" Which was true. So its ready to go. hopefully collecting the Caliper from work tomorrow.

 

The Rounded wishbone bolt and nut is £12 from A.R and will have it thursday. Quicker than anyone else. If i knew the grade of steel and the dimensions, id just grab any bolt which meets the requirements. but that still needs to be cut off with an Angle Grinder.

 

hopefully it will be back together Thursday, Then ill be bleeding the whole brake and clutch system. Meaning it should be ready for Friday.

 

 

Quick question. it has Brembo 4 Pots as standard, with two bleed nipples, which order shall i bleed them? Closer nipple first?

Closest (to the car) first. Then outer, working the air away from the car! Good progress dude

After bit of a faff, i was able to get the brake caliper sorted.

Now its on the car. Tomorrows job is to fit a new wishbone clinch nut and bolt and then bleed the brakes. Bit unsure of how im going to bleed thr ABS pump however.

Like VAG you can tell it to pump however the OBD lead is different. You have a separate pin for each ecu.

One for the engine, one for ABS and one for the airbag.

So you have to sort of jumper wires about to throw it together

That red will look stunning after correction and coating

You mean a full respray.

Haha the bonnet is flat and the rear bumper is pink

You mean a full respray.

Haha the bonnet is flat and the rear bumper is pink

You'd be surprised :P

I'll take my DA to it

Update.... its NOT going to combe.

Problems list:

1) After refitting the caliper i bleed the wholes system but my laptop would not connect to the ABS ecu. Therefore I have air in the ABS module which i cannot purge. So as i found out on my test drive. I have spongey brakes/pedal

2) Rear nearside bleed nipple is so rounded i cannot undo it. My fault. Time for a replacement caliper

3) GTV's naturally run a bit of camber and the rear nearside is down to the canvas on the inner edge.

4) resonance/rattle. At 2500 rpm there is a resonance which i cannot stop. This is because of two brackets on the subframe which i omitted due to it being a PITA has now bitten me back as despitr how many cable ties i use. its still rattling

5) Misfire. Probably a coil pack. But it flashes the injector warninh light like mad when accelerating above 4500rpm under load. I cant know for definite however as the obd2 alfa ecu reader software (multiecuscan) costs a fair bit and thr free version does not allow access to the ECU. as well as my previous problem of not being able to get it to work on my laptop.

so with going to work tomorrow. Im not going to have enough time to sort out the problems

That sucks big time Taylor! :( Was so looking forward to hearing your Alfa!

Not right now with the resonance and the misfire. :(

Need a full weekend... oh wait its bedford the week after....

Still blows buddy, still coming up I hope? You can always come round with me and tell me what direction to take at the next bend....

:(

 

That is all.

Gutted is an understatement.

If it a busso v6 in a kit car... id be happy.

End of the day i bought a dream car. And its being a typical one. So far im starting to dislike everything except the engine and gearbox