Alfa Romeo Alfetta Instruction manual

TRANSMISSION· SUSPENSION
VEHICLE HEIGHT AND GEOMETRY
STEERING GEAR· BRAKES
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This publication is intended
for the use by the ALFA ROMEO Service Organisation
and contains instructions for adjusting, repairing and
overhauling the transmission, suspension, brakes and steering.
The operations are
fully illustrated in order
to facilitate the identification of the parts or units in question,
of the tool or jig to use, and the correct way to proceed.
The replacement
of separate units or parts must be carried
out
using
only
genuine
ALFA ROMEO
components.
Only by
this means
can the complete interchangeability
and perfect performance
of the various parts be ensured.
When ordering please specify not oniy
the type of car and the part number from the Spare Parts Catalogue,
but also the chassis and engine serial numbers.
When repairing and overhauling we also recommend strongly the
use of special tools. Finally, this Manual should always be kept
up-to-date with the data and information received through the
'Service
Information Sheets' and the 'Up-dating Instructions'
which are issued periodically by the Technical Service Department.
Alta Romeo
Service Department
Public. n° 2064·Workshop Manual November 1975
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CONTENTS
3
Workshop standards
58
VEHICLE HEIGHT AND GEOMETRY
58
To check vehicle height
60
To adjust vehicle height
4
TRANSMISSION
62
To check geometry
6
To remove propeller shaft from the car
66
Tools
8
To dismantle propeller shaft
12
To reassemble propeller shaft
13
Refitting propeller shaft to car
67
STEERING GEAR
15
To overhaul the half shafts
68
To remove the ZF steering rack from car
18
Tools
69
To dismantle the steering rack
21
Tightening torques
70
To reassemble the steering rack
22
Lubricants and sealants
73
To refit steering rack to the car
73
To remove the steering column from the
car
23
FRONT SUSPENSION
74
To dismantle and reassemble the steering
2.4
To remove the front suspension
column tube
26
Dismantling
75
To refit steering column to car
29
Re-building
76
Partial operations
31
Re-fitting the suspension
80
Tools
32
Partial operations
83
Tightening torques
36
Tools
83
Lubricants and sealants
40
Tightening torques
40 Lubricants, anti-seizing
compounds
85 BRAKING SYSTEM
86
To dismantle the front brakes
87 Tests
and checks
41
REAR SUSPENSION
88
To refit the front brakes
42
To remove the rear suspension
89
To dismantle rear brakes
45 Dismantling 90 Tests
and checks
48 Re-assembling
92
To refit the rear brakes
48
To reconnect the suspension
93
To remove and refit the servo assembly
49 Partial
operations
96 Brake pipes
52 Rating
data for calibrating and matching
100
To bleed brake system
front
& rear
shock absorbers
102
To overhaul the handbrake assembly
54
Tools
106
Tools
57
Tightening torques
107
Tightening torques
57
Lubricants and anti-seizing compounds
107 Lubricants, fluids
and sealants
2 November 1975 Public.
nO 2064-Workshop Manual
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WORKSHOP STANDARDS
When dismantling and reassemblying, always use appropriate spanners, extractors and tools (both
general and special tools) and
not improvised devices, so as to prevent damaging the parts.
To release tight components, tap lightly using only a copper or aluminium hammer, if the parts
concerned
are made of ferrous materials, or a wood or plastic head mallet, if the parts are made
of light alloy (covers, housings, etc.).
Neatly separate the parts belonging to the various units and partially screw the
nuts on their
corresponding studs or screws.
When dismantling, check that the parts that
are to be aligned have a reference '< number or a
distinctive mark
on them.
If
it is discovered that a pr'lviously replaced part has not been aligned
with such a mark, one should be applied.
Before washing the parts, remove all dirt with a brush and rags (to avoid excessive contamination
of the cleaning fluid). Then wash the parts with paraffin or a suitable fluid. Remove any surplus
with a compressed air jet. Dry the parts immediately after washing, to avoid corrosion.
After sandblasting or grinding with abrasive discs, etc., wash the parts thoroughly and blow off
with compressed air to remove completely all traces of abrasive material. When reassembling, use
compressed air or a dry clean brush to clean the parts (especially those that have been machined
or ground).
When re-assembling, lubricate the parts adequately (except graphited bushes) to avoid seizure
during the initial running period.
When coating parts with a lubricant use specially clean brushes and
oil. Protect the containers
from dust and use them exclusively for this purpose.
When re-assembling, replace seals, oil seals, gaskets, flexible washers, lockwashers and lock plates,
"Palmutter" locknuts and any other parts that appear to be in a doubtful condition.
Use exclusively genuine ALFA ROMEO spare parts
Public. n° 2064 · Workshop Manual November 1975 3
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Public. nO 2064-Workshop Manual
TRANSMISSION
A peculiarity of the Alfetta is the
layout
of the transmission.
This car differs from conventional cars
as it has the clutch and gearbox unit
mounted in unit with the rear axle.
This assembly
is connected with the
engine by means of a two-piece propell-
er shaft. The connection at either end is
achieved by means of a flexible coupl-
ing.
The location on the body
is by means
of a central support fitted with ball
bearings.
The drive from the differential
unit , to
the rear wheels is by means of half
shafts with constant velocity joints.
These shafts are necessary owing to the
De Dion type rear axle layout chosen
for this car.
This type
of axle achieves a reduction
of the unsprung weight and improves
therefore the stability under any driv-
ing condition.
November 1975 5
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TO REMOVE PROPELLER
SHAFT FROM THE CAR
Place the car on a ramp.
-Slacken clip 2 connecting the front pipe to
the rear pipe;
-
unhook the flexible supports 3 from the
front crossmember supporting the rear axle
assembly;
-Remove gaiters 7
from the gearlever support.
-slacken and remove the bolts connecting the
flanges 4 which retain the exhaust pipe 5
against the
manifold;
-slacken and remove bolt 6 fixing the
exhaust pipe
to the bracket situated on the
rear engine
mounting and lower the pipe after
separating it from the rear section.
-Slacken and remove the screw and washer 8 retaining shaft 9 against the selector lever. Slacken
and remove the nuts and washers 10
of the flexible coupling connecting the rod to the lever on the
clutch housing. Lower shaft.
6 November 1975 Public.
nO 2064-Workshop Manual
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Rotate propeller shaft in order to be able to
unscrew both one of the set bolts fixing the
shaft
to the flywheel and one of the set bolts
fixing shaft to the clutch.
Remove the small flywheel cover
from the
rear engine housing.
Lock the flywheel by means of tool no.
A.2.0290 which is fitted in place of the cover.
Release and remove the above mentioned fix-
ing bolts using spanner no A.5.0192 (1).
Publi c. nO 2064 - Wo rkshop Manu al
Remove the flywheel locking tool and unscrew
the remaining
fixing bolts on the propeller
shaft, using the
same procedure.
Unlock and remove the nuts and washers fix-
ing the propeller shaft centre support to the
studs.
Disconnect the rear engine
mounting from the
body by unscrewing the retaining nuts. The
washers should
be retained as they are used on
assembly
to determine the distance of 7 ± 1
mm between the propeller shaft and the
top
of the support. Th is clearance is required to
prevent any fouling. Withdraw the propeller
shaft
from the clutch.
Proceed
with care in order not to damage the
grease -retaining rubber cup 2 between the
flexible coupling and the clutch fork.
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Withdraw the propeller shaft from the tunnel,
working from the rear of 'the car, disconnect-
ing the centre support
from the studs and the
front bush from the flywheel spigot
simulta ~
neously with the front flexible coupling.
TO DISMANTLE ,
PROPELLER SHAFT
Disconnect the front section of the shaft from
the rear portion. Proceed as follows:
-Suitably mark the respective positions
of
the front and rear shaft. Fit tool no. A.2.0263
to the flexible coupling. Release the bolts
8 November 1975
between shaft and flexible coupling and
remove them
with their washers.
-Separate the
two shaft halves.
Front flexible coupling
-Clamp the front shaft in a vice. Fit tool no.
A.2.0263
to the flexible coupling and remove
the protective rubber cap. Disconnect the
coupling from the flange unscrewing and
removing the
fixing screws and washers.
-Remove the circlip 1 using the special pliers.
Extract the washer 2 and the spring 3.
Public. nO 2064·Workshop Manual
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