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 F***ing gearbox 
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
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Post F***ing gearbox
Gearbox is chucking out oil from the speedo sensor hole and from the front somewhere too, so yet again its all got to come out.

Apart from the speedo oil seal and possible front nose oil seal, is there any other seals or parts i should replace as a matter of course whilst its out?


Fri Jun 17, 2016 10:51 pm
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Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
Make sure only 1.6lts of oil plus a nice large breather hole . I think we talked about this before though.

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I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Sat Jun 18, 2016 9:31 am
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
Got both of those so all good on that front


Sat Jun 18, 2016 4:16 pm
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Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
Pete&Matt wrote:
Got both of those so all good on that front

Another tip would be -- don't use the input shaft to lift the box :!: Buggers the oil seal :wink:

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Sat Jun 18, 2016 9:56 pm
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
I see that BGH do a lubrication upgrade for 2nd and 3rd gear. Any idea what it is and if its worth doing?

Worth changing to the needle roller bearings on the laygear that they do as well?


Mon Jun 20, 2016 6:13 pm
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Stylus owner

Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3709
Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
He cuts an oilway basically , mines all sorted at the last rebuild several years ago

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Mon Jun 20, 2016 9:02 pm
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
got the box all out. The bolts have been leaking on the front nose that the hydraulic clutch bolts too, so that is the cause of the leak there.

Before I put it all back together, which grade of Loctite do you use? 243? torque setting? Did you use the cork gasket or use a gasket sealant? I had the cork gasket that the clutch came with.

The shaft seal is fine and was new anyway, so was nice and dry.

The speedo drive, where I cut it down for the electrionic unit, it had removed the metal sleeve on the drive unit and therefore the seal was not in contact with it! Got a spare though so will sort that out.

Will enlarge the breather again and now have a syringe, but it is going to be bloody tight, if not impossible to get the cover back on when the box is in. I have an ally panel above the box which is all riveted in place. Might look at using a push lock connector and running a small tube to a higher point, which will give it some space to blow the oil out too and come back again?

Cheers

Matt


Thu Jul 07, 2016 10:01 pm
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Joined: Fri Mar 10, 2006 8:49 pm
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Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
Key point with those bolts to gearbox is , really dry clean out those threads because they aren't stopend holes , they go through to the box , hence oil :wink: I used the ''blue stick'' type as it was there , then upped the bolt size advised torque by 3 lbft . Don't recall the advised but probably about 12 lbft :?: Just google it for steel threaded holes . Be very careful with the ally threaded though , I did up it slightly but again don't recall the advised lbft. A figure of 11 rings a bell :?:
Regarding that syringe cut off length , it only needs 30 or 40mm's tube length not counting the ' nose ' , so should be easy enough to get in there and it won't need a tube connected to a higher level . The piece of syringe will never fill up , it'll just hold dribbles of oil due to breathing pressure , mine gets spun up a lot more than yours will without holding oil , maybe just half a thimble full .

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Fri Jul 08, 2016 10:57 am
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Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
I will put them in with Loctite 577, they will never leak again then!

Do you use the cork gasket on the housing or something different?


Fri Jul 08, 2016 11:34 am
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Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
I used the cork gasket but smeared silicone gasket seal each side -- belt and braces , as it's such a damn chore to remove/refit the engine

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Fri Jul 08, 2016 2:51 pm
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
All done now and just waiting to put it back in the car. Inner wings to be done first whilst I have the extra space!

If it leaks this time, it coming out and staying out!!


Thu Jul 21, 2016 11:21 am
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
Engine and box are all back in now. I put 1.6 litres of oil in the box, but the level was then above the filler plug by quite a long way. So took some out until it was level with the bottom. Was about 1 litres in total in the end. Did drain all the previous oil out too.

I had a look at another Type 9 box I have and that has a big bulge in the bottom of the casting at the front whereas mine doesn't. This would then give it the extra capacity. Maybe a later box?

matt


Thu Aug 18, 2016 9:29 am
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Location: ASTON CLINTON BUCKS
Post Re: F***ing gearbox
H'mmm , a litre doesn't sound much in a box , I used to put the advised 1.9lts in type 9's --- strange :? Only started putting 1.6lts to avoid cavitation . To cover you backside , you could add ZX1 Extralube at the leaflet advice for box's , around 50ml rings a bell :?: I run it in engine oil , gearbox , ATB diff , water radiator and fuel . Hence my engine is still original with no rebuild since fitting in 1999 ----- that's mostly track miles too in 17 yrs .

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Thu Aug 18, 2016 9:44 am
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
will see how it goes. My father in laws Type 9 took a similar amount too and has been fine for the last 2k odd miles since a rebuild and has a Essex V6 on it to strain it a little!


Thu Aug 18, 2016 9:51 am
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Stylus owner

Joined: Thu Mar 09, 2006 4:08 pm
Posts: 614
Post Re: F***ing gearbox
ran it all up to temperature today and there appears to be no gearbox leaks! yippee!

Just to sort out the spark plug failing issue next!


Tue Aug 23, 2016 10:24 pm
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