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.
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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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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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_____________ R_ E_M __ O_V_A_L _____________
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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.
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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.
November 1975 7
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D _
s
_ M _ A _ N _
T
_
L_N_G
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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.
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DISMANTLING
\I]JJ
TRANSMISSION
-Extract the spherical seat and the bush from
the flange on the front propeller shaft, using
extractor no. A.3.0361.
Replace the spherical seat and front bush,
proceeding as follows:
Using Molykote paste G Rapid, lubricate
the
working surfaces of the new spherical seat and
the new bush.
Place
the spherical seat inside the bush and
insert
them together in the flange, using
special tool no. A.3.0246.
• g
Locate in the front bush: spring, spring
seating washer
and circlip.
Re-assemble
the flexible coupling to the front
propeller shaft. Ensure that the holes align
Public. nO 2064-Workshop Manual
with the centering pivots. Tighten the fixing
bolts to 4.9 to 5.3 kgm; if the transmission is
of the type with interference mounted bolts,
fixing nuts must
be
tightened to
4.4
to 4.9
kg.m.
Remove tool no. A.2.0263.
Fit protective cap and fill the front bush with
approx. 5 cm3 of Molykote BR
2 grease,
lubricating also its external surface.
Warning: The
front bush may also be disman-
tled when the flexible coupling is mounted on
the shaft flange. It is sufficient to remove the
protective rubber cap.
Centre
support
Remove flange 1 and centre support
2 from
the shaft, using a press. Proceed as follows:
-Mark flange
and front shaft in order to faci-
litate
the assembly.
-Remove spherical seat 3. This
is provided
with a slot for
the use of general tools.
Proceed with care. If there is no slot, use tool
no. A.3.0261.
-Unlock and remove fixing nuts 4 on the
flange crnd support, using a ratchet and hexa-
gon
socket spanner.
March 1978 9
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D_s_M
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-Remove the flange from the shaft, .using a
press and semi-circular plates no.
A.2.0248.
NOTE: Great care should
be
taken. in order to prevent any
damage to the flange which cannot
be replaced
without af-
fecting the balance of the complete shaft.
-Remove centrifugal cap.
-Remove the centre support, using a press and
the semi-circular plates, no. A.2.0247 at this
stage
the other centrifugal cap is damaged and
must be replaced when re-assembling.
10 November 1975
Replace the centre support bearing as follows:
-Remove bearing retaining circlip, using
special pliers.
-
Extract the ball bearing, using a press, and
special base, tool no.
A.3.0265/2 (1) and tool
A.3.0401 (2).
2--- ...
-Fit the bearing in the centre support, using
fitting tool no. A.3.0401. Retain with circlip.
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D_s_M
__
A_N_T_L_N_G
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Apply sealant Loctite 242 to the seat of the
centre
support and the seat of the flange.
WARNING :
Before applying the sealant, all traces of old
sealant should be removed by scraping and blowing the sur-
faces clean. Degrease
the surfaces using trichloroethylene or
chlorothene.
Fit a centrifugal cap on the front shaft and
insert the centre support
with the other
centrifugal cap.
Refit the flange ensuring that the previously
applied alignment marks are
correctly posi-
tioned.
Fit the nut retaining the flange on the shaft.
Tighten
to 9.5 to 10.5 kg.m and fit locknut.
Check that the spherical seat on the rear
flange
is in good condition. If necessary,
replace
as follows:
-Remove circlip (where fitted), using special
pliers, and
extract the spherical seat from the
flange.
-
Fit a new spherical seat, using tool no.
A.3.0244 and retain with circlip.
Complete the assembly
of the front propeller
shaft
by refitting the sphericaJ seat after
lubrication of the working surfaces with
Molykote paste G Rapid.
Centre coupling on rear shaft
Clamp the rear shaft in a vice.
Mark the position
of the coupling in relation
to the shaft.
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Remove the protecting rubber cap from the
front
bush of the rear shaft, after having
removed the retaining ring.
Fit tool no. A.2.0263 to the coupling.
Remove the centre flexible coupling from the
rear shaft
by unscrewing and removing the
retaining bolts and washers.
Refit the centre flexible coupling, and ensure
that the housing holes are aligned with the
centering doWels on the flange
of the rear
shaft.
Fit the retaining screws · and washers and
tighten
to 4.9 to 5.3 kg.m; stop nuts must be
tightened to 4.4 to 4.9 kg.m.
Refit the rubber protection cap to the bush
on the rear shaft and secure
by means of the
sealing ring. Lubricate the cap and the bush
with approx. 7 cm3 of Molykote BR 2 grease.
Remove tool no. A.2.0263.
Rear coupling on rear propeller shaft
Check the
condition of the flexible coupling
and dismantle
it as follows :
-Mark the position
of the flexible coupling in
relation
to the flange on the rear shaft, in
order
to facilitate the re-assembly.
- Fit tool no. A.2.0263 as previously describ-
ed and disconnect the coupling from the
flange
by removing the fixing bolts and
washers.
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____________ D_'_s_M _A_ N_T_L_'N_G ____________
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-Remove the rubber protection cap 1
from
the flexible coupling, after having previously
removed the retaining ring.
Check the condition of the spherical bearing
and
if necessary, replace it together with the
corresponding spherical seat. Proceed
as
follows:
-Where
fitted, remove the circlip that re -
mains in the spherical bearing, using the
special pliers.
-
Extract the spherical bearing together with
the spherical seat, using extractor no.
A.3.0261.
If the spherical seat is provided
with a slot, use general tools.
-Insert the spherical bearing in the spherical
seat,
after having previously lubricated the
working surfaces with Molykote G Rapid
compound.
12
March 1978
- Fit the spherical bearing complete with seat
3 on the spider, using special
tool no.
A.3.0244, (2) and secure
with circlip.
-
Fit the rubber sealing cap to the bush of the
rear flexible coupling and secure
by means of
the special ring.
-Re-assemble the flexible coupling; align the
marks previously made and ensure
that the
locating holes
are aligned with the centering
pins on
th .e flange.
-
Fit the bolts, flexible coupling to flange,
and tighten
to 4.9 to 5.3 kgm (for stop nuts,
4.4
to 4.9 kgm).
-Lubricate the bush and the grease cap of the
flexible coupling, using approx. 7 cm3
of
Molykote BR 2 grease, and fit the grease
retaining cap (which will remain interposed
between the gearbox spider and the rear
coupling), locating its
lip over the bush of the
coupling itself.
TO REASSEMBLE
PROPELLER SHAFT
Re-assemble propeller shaft by aligning the
marks on the flexible coupling and the centre
spider. Connect the
front propeller shaft to
the .rear shaft and tighten the bolts, using
spanner no. A.5.0192 and a
torque wrench
(300
to 400 mm) to 4.1 to 4.5 kg.m.
The
lock nuts on the propeller shafts and the
fitted bolts must be replaced and tightened,
using the above spanner,
to 3.8 to 4.2 kg.m.
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__
R_EFITTING_~
__ _
\(jJJ TRANSMISSION
REFITTING PROPELLER
SHAFT TO CAR
To refit the propeller shaft, proceed in the
reverse order,
noting the following:
Lubricate, if this was not carried out during
the overhaul, front bush and spherical seat of
the rear coupling provided with grommet, by
applying 5 and 7 cm3 respectively of Moly-
kote BR 2 grease; if necessary, add 2 cm3 of
the above mentioned grease to the bush of the
engine flywheel.
Lock the engine flywheel, using tool no.
A.2.0290, as for the dismantling, and insert
the bolts fixing the propeller shaft to the
flywheel and the spider on the
clutch end.
Tighten the bolts, using spanner no.
A.5.0192
and a 3000 mm. torque wrench, to 4.1 to 4.5
kg.m.
Clean the thread
of the studs fixing the
coupling
to the gear control rod and fit the
nuts and tighten to 2 to 3.25 kg.m.
The above operation applies
to flexible coupl-
ings. For solid couplings, proceed
as follows:
fit loosely the gear control rod and the fixing
nuts of the coupling. Engage 5th gear and
tighten the nuts
to
the above mentioned
torque.
Remove
tool no. A.2.0290 and fit in its place
the small cover plate on the flywheel housing.
Reconnect the rear engine
mounting, using
the displaced washers
to ensure the correct
distance between shaft and top of support,
i.e. 7 ± 1
mm.
Refit the exhaust pipe by reversing the re-
moval operation.
Public. nO 2064-Workshop Manual
To check tightness of flexible couplings
This
is the only operation required to be
carried out when servicing the car, with no
need to disconnect the propeller shaft. This
check
is not required on propeller shafts using
safety locking nuts.
Check tightening
torque of all coupling secur-
ing bolts, which must be within 4.1 to 4.5
kg.m using the appropriate special tool.
Proceed as follows:
Disconnect the exhaust pipe, as described on
Page
6.
Remove the small cover plate from the
flywheel housing and fit in its place tool no.
A.2.0290
which locks the flywheel. Secure the
tool with small bolts.
-Check the tightening torque of the rear and
front
bolts on the rear coupling, using spanner
no. A.5.0192 (1) and a torque wrench.
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R _ E _ F _  _ TT _ _N_G
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-Check tightening torque of bolts on central
coupling.
- Front bolts, use special tool no. 2
(A.5.0190) and torque wrench.
-
Rear: bolts, use special tool no. 3 (A.5.0191)
and torque wrench.
14
November 1 975
-To check tightening torque of bolts on
front coupling.
-Front bolts,
use
special tool no. 1
(A.5.0191) and torque wrench.
-
Rear bolts, use special tool no. 2 (A.5.0192)
and torque wrench.
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~f)
TRANSMISSION
-- .
--
OVERHAUL
TO OVERHAUL THE
HALF SHAFTS
INTRODUCTION
It should be noted that any damage to the
rubber boots means the
loss of the lubricant
and ingress
of foreign matter, which will
prevent the constant velocity joints from
working correctly.
To replace constant velocity joint boots
Place the car on a ramp and raise the rear
wheels
by means of a suitable jack.
Slacken the bolts securing the
half shaft to
the brake disc spacer and to the hub shaft.
Remove the
half shaft, retaining the fixing
bolts, washers and plates.
Clamp the
half shaft in a vice, remove the
boot by separating it from the retaining clips
and pushing
it back along the shaft, to enable
the constant
velocity joint to be dismantled.
Remove the
outer cover from the joint and
carefully clean the external part
of the joint
with rags. Do not use solvents.
Remove the
circlip retaining the constant
velocity joint, using suitable pliers.
Mark the
joint in respect of the shaft.
Public. nO 2064-Workshop Manual
Remove the joint from the shaft, using a press
and semi-circular plates A.2.0247 (1), the
base, tool no. A.3.0487 (2) and tool no.
A.3.0479 (3).
Finally, remove the cup spring and the boot.
Replace the boot, taking care not to damage
it when pushing it over the splines of the half
shaft. Tape the splines to provide the neces -
sary protection.
Fit the cup spring to the half shaft.
Fill the inner and
outer chambers of the joint
with 70 g. of Molykote VN 2461 C grease or
Optimol Olistamoly 2 LN 584.
Refit the joint to the half shaft, aligning the
marks made
prior to dismantling it. Place the
assembly under a press, and using the semi-
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circular plates, No. A.2.0247
(1),
the base,
tool no. A.3.0487 (2) and
the
inserter, no.
A.3.0386 (3) as illustrated.
Refit
the circlip, ensuring that it is seating
correctly
in its seat on the shaft.
Ensure
that the grease-retaining rubber seal is
on the outer ring of the joint; apply Curil K2
sealant and fit the outer cover.
Apply some Bostik
475 or U.S.M. 475 to the
surface between the boot and the inner cover
of the constant velocity joint.
WARNING:
It is recommended
to
apply the boot sealant
un i formly and in suffic i ent quantity ,
to
prevent , in time , loss
of grease. It is also recommended that only the clamping clips
of the type supplied by our Part Department be used, in
order
to
pre v ent any out - of-ba l an ce c ond i tion of the half
shafts .
16
March 1978
Place the boot on the jointand in the seat pro-
vided on
the inner cover and on the shaft in
the space between the ribs. Position the retain-
ing clips and tighten with special pliers no.
A.2.0288/0035 and A.2.0288/0062, taking
care
not to damage the boot.
Reconnect the half shaft and lubricate the
thread of
the retaining bolts with Molykote
BR 2 grease. Tighten bolts to 2.8 to 3 kg.m. .
0<'
The half shafts are symmetrical and therefore
interchangeable. The above operation thus
applies to all the constant velocity joints of
both half shafts.
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TOOLS
TIGHTENING TORQUES
LUBRICANTS AND SEALANTS
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TOOLS
~
~
.. .
~
.--;:--.
_ . _...I L. _. _ _
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-1- __ -"-
~
_ _
18
Mar ch 1978
A' .5.0190
SPANNER
17 mm Bi -hexagon spanner, L-shaped, for
front bolts of centre coupling
A.5.0191
SPANNER
17 mm Bi-hexagon spanner, L-shaped, for
front bolts of front coupling and rear bolts of
centre coupling,
A.5.0192
SPANNER
17 mm Bi-hexagon spanner, L-shaped, for
front bolts of rear coupling and rear bolts of
front coupling
A.2.0247
*
SEMI-CIRCULAR PLATES
for removing the centre support of the front
propeller shaft and for extracting and insert-
ing constant
velocity joints on the half shafts,
A.2.0248
*
SEMI-CIRCULAR PLATES
for removing spider from front propeller
shaft,
A.2.0315
'iF
CLAMP
For fitting front, centre and rear couplings
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