Lancia Motor Club

Model Technical and Interest => Flavia => Topic started by: bobhenry999 on 12 April, 2012, 10:41:52 PM

Title: Gearbox removal/refit
Post by: bobhenry999 on 12 April, 2012, 10:41:52 PM
How easy/difficult is it remove and refit the gearbox in a Flavia Coupe ?
Its one of the jobs, that over the last 30 years of Flavia/2000 ownership I have never had to do.
Can it be done at home, on axle stands/ramps. Are there any particuler problems that I should be aware of ?

Any help would be appreciated.


Title: Re: Gearbox removal/refit
Post by: rogerelias on 13 April, 2012, 06:59:06 PM
Fairly easy from memory,jack up as high as you can on axle stands, drop the exhaust off ,whole system in one lump, gearlever out, undo driveshafts at the inner end, all bolts around bellhousing, I think there is a crossmember that unbolts, trolley jack under the box and remove, all easy from underneath, i think thats it, its not a hard job, and no special tools needed.Good luck.

Title: Re: Gearbox removal/refit
Post by: bobhenry999 on 13 April, 2012, 09:05:01 PM
Thanks for that, I think i`ll give it a go then.

Title: Re: Gearbox removal/refit
Post by: LanciAlan on 14 April, 2012, 07:23:03 AM
And disconnect the reversing light switch wires!!

I hope it is as easy from below as it sounds! This is probably the approved method for gearbox/clutch removal though I have never done it this way and, as these are heavy gearboxes, I think it would require quite some dexterity and strength while rolling around on the floor if the car can't be raised on a full hoist.

Removing the exhaust manifold can also become challenging if, as on my later cars, it is fixed with 8 smallish Allen bolts that are seized and easily strip. Also, the full exhaust system cannot be dropped down from the car without splitting the middle and rear boxes as it passes over the rear axle with a box fore and aft. However I would think it can be swung to one side enough to get the gearbox past.

You might want to consider the other approved method of removing the entire "propelling unit" (i.e. engine, gearbox and subframe) by undoing the 6 subframe mounting bolts and raising the car off it though this involves disconnecting more stuff, including steering column, brake lines, electrical and cooling/heating plumbing and you still have to undo the exhaust (bot not remove it). It may also provide the opportunity to attend to other jobs around the engine/subframe and clean up the engine bay itself.

Even when approached from above with the subframe out like this, the gearbox is a bit of a tight squeeze to remove from the subframe and the lower crossmember under the box still has to come off.... but access and visibility are generally better and the heavy gearbox remains below your head at all times!

Here is a pic of mine going back in (and for some reason without driveshafts or wheel hubs fitted) so you get the idea.


It actually came out a different way as a clutch problem (which I decided to approach by removing the engine - also a tight squeeze but again working from above) turned out to be a gearbox failure (so the subframe and gearbox followed later). In this pic the old gearbox is still in the car and the replacement is on the floor.


Title: Re: Gearbox removal/refit
Post by: fay66 on 14 April, 2012, 09:05:40 AM
Crikey Alan, That's one heck of a big lump :o

8227 8)

Title: Re: Gearbox removal/refit
Post by: LanciAlan on 15 April, 2012, 12:21:48 PM
Actually when viewed on its own (I cleaned it on the bench and reassembled it on the bed of a small trailer) I considered the engine/gearbox assembly  to be a thing of quite some mechanical beauty ... in a low-slung and purposeful way.



Title: Re: Gearbox removal/refit
Post by: simonandjuliet on 15 April, 2012, 05:55:11 PM
It IS a work of art - I  like the cam cover bolts being lined up nicely !

Title: Flavia/Fulvia gears
Post by: angelorange on 22 April, 2012, 03:49:56 PM
Do any flavia owners have a 5 speed in bits?

For Fulvia 5 speeds (excluding piggyback 818-540)  there are 2 gearbox types in terms of pinion gear design and internal diameters.

Pics on this thread:

Let me know if you can help find a 40 tooth 1st pinion gear and hub with 48mm internal diameter.

Title: Re: Gearbox removal/refit
Post by: rogerelias on 22 April, 2012, 05:22:14 PM
Have a Vignale 4 speed in parts, if that helps