GTV 2000 Gearbox rebuild questions

[Captain Slow]

Hey folks

I'm having a crack at rebuilding a gearbox for my 74 gtv.
I purchased virtually a complete gearbox in parts a while back. It came with some new selector forks, synchro rings, and some other parts.
I've never rebuilt a gearbox before, but the old Italian chap I bought all this stuff from said everything was there to do the job.
Apparently he used to own or work at an Italian specialist workshop I believe and was selling off a whole bunch of stuff that had accumulated in his garage over a few decades.

Anyway, i've had a go at a test assembly and run into a bit of trouble as I cant seem to get the three triangular shaped objects (please forgive my ignorance!) onto the main shafts.
Do these need to be heated in order to be fitted? Either that, or i'm not trying hard enough, or i've got incorrect parts.

I've attached a few pictures to help. The triangular bits i'm talking about are at the bottom of the first picture.

I'm sure i'll have a lot more questions, but any general advice would be very appreciated. If anyone knows of a detailed rebuild guide that would be fantastic.

Thank you
Kind regards to everyone
Ben

[festy]

There's gearbox manual scans on the 'bb:
http://www.alfabb.com/bb/forums/transmissions/164216-giulia-gear-box-manual.html

[AikenDrum105]

They are a tight fit - heat will definitely help,  and then a bit of steel tube and a hammer (or a long puller from the other side)    

You need a decent puller / hydraulic press to get them off...    Have you got a copy of the factory gearbox destructions ? (I think you'd have to, to get the it back together from a bag of parts   )  

^^ Edit:  What Festy posted above while I was still spell-checking


Remember when renewing / swapping synchro rings and collars around - to check the ID of the sliding collars as well - you want the tightest synchro <> collar fit on the big gears 1->2  and 2 ->3.  I got it backwards once and put a new synchro ring on 1 ->2 but got the loosest collar there by mistake - grunching from the get-go..   Gutted.  

There's an interesting thread worth reading about repro synchro rings on the alfabb too http://www.alfabb.com/bb/forums/transmissions/186105-syncro-ring-issue-race-cars.html    

Great fun !

[Captain Slow]

Thanks guys that's very helpful

I had a read through the tear down and rebuild manual and lets just say my previous "can do" attitude is wavering lol.

I've been to a local gear and diff place and he thinks he can do it. He says he charges around $600 labor for something like a T5, but seeing as the alfa box is a bit different, plus he'd be figuring it out has he goes, the price will be somewhere over that amount.
How reasonable does this sound?, and what might I be expecting an alfa specialist to charge to do it just in labor?

Obviously i'd rather have someone doing it that has done one before, but there will definitely come a price point cutoff where i'll just try to do it myself. I'm told challenging ones self builds character 

Or alternatively, do any forum guru's (preferably in NSW) have the inclination to do the job in their spare time? Paid of course.

Regards
Ben

PS, i've read about gear lightening, and swapping one gear or something from a spare from another box (might be the other way around)
I'm sure this all helps, but how important is that stuff? I'd like to do the job properly so while it's apart, any worth while mods etc might as well get the nod.
Having said that, the basic rebuild *might* be in my scope of ability, but not too much extra stuff like that. Especially anything requiring machining.

[Paul Byrne]

I would strongly suggest you do it yourself. It is straightforward if you follow the manual. But--- you do really need a bench press to make it easy. A compact 6 ton press from Supercheap or whatever is less than $100 and incredibly useful for many jobs. I can't understand how I survived without one. Only suggestion here is to press components off or on to the mainshaft one at a time using suitable bits of plate and the press. Do not push all the bits off or on in one go.

I recently did my gearbox to fit close ratios and at first was concerned it was beyond my ability/tools. It was actually no problem even though for other reasons (new gear not original width) I had to reassemble more than once.

Obviously you need to look at the gears for any chips etc.- almost certainly ok. But carefully check the engagement dog teeth on both the gears and the sliding rings (those bits in your photo are the mainshaft drivers that transfer the torque from an engaged sliding ring to the shaft). The teeth should have reasonably sharp points and none should be missing. Bearings are probably ok -but check and replace if necessary.

Be very careful when removing and replacing the selector forks. Make sure that you don't lose or fail to refit the 3 spring loaded locating balls, and especially the three small shaft interlock sliding pins.

Only other thing I can think of is to suggest that you use Loctite 518 sealant for all the assembly joints. Do not use silicone.

[Captain Slow]

Thank you for that encouraging post. Sorry I haven't checked this thread in a while.

I think i'm going to go for it. I've got my new press set up, but i'll probably wait till after summer to do the job now.

I'll update here when something happens!

Ben