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  1. #1
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    Default clutch removal etc.

    Now Alfa Island is over I have decided to try to chase down an oil leak that I have that is getting worse with each race meeting, and at the same time check out the clutch that has been slipping at high boost. So I have removed the lower cross member and tomorrow i will remove the gearbox. Also attached is a pic of one of the IC hoses - can you believe that I had this system maintaining 1.45 bar boost with a hole this big!
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    Wow, it was falling off boost at one stage wasn't it? That could be the reason. It will make more power after fixing that up too!

    It looks like CV grease from the inner CV has sprayed out.

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    Ah, the common problem with that hose
    They never last very long. I have used three of them in 7 years time 2 new and one used. I think they are getting to warm/hot.

    Regards,
    Mac
    In a world full of compromise...
    ...some don't.
    ___________________________
    Opel Astra Sports Tourer 110HP 2017
    Alfa 147 1.6 16V 120HP
    Alfa 155 Q4 2.0 16V turbo

  4. #4
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    I'm going to change the same hose later this morning and it's just 2 years /15.000 Km old with oem boost.
    Next time I'm going to search for a silicon {or similar} one.
    Nick

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    Quote Originally Posted by SteveNZ View Post
    It looks like CV grease from the inner CV has sprayed out.
    Nah, looks too thin for that, it's dripping from the steering rack gaiter.

    I'm guessing it smells like gearbox oil...

    wrinx
    My Q4 in the Garage

    www.alfaromeo155.co.uk ............................ □□□-V-□□□ .................................. www.ilmostro.co.uk

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    ~Well, I have the lot.. there is engine oil in volume, some CV grease and gearbox oil. I am going to fix them all!

  7. #7
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    Which are the diameters of that hose? 3" to 2.5"?

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    From memory, 76 to 89 mm.

    Regards,
    Marc
    In a world full of compromise...
    ...some don't.
    ___________________________
    Opel Astra Sports Tourer 110HP 2017
    Alfa 147 1.6 16V 120HP
    Alfa 155 Q4 2.0 16V turbo

  9. #9
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    Sure it?s 76mm ?? I thought it was less...

    So this would be a good replacement:

    >link<

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    its less, i thought 67mm

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    I got the gearbox out today - not bad seeing as the first time I did it, it took me two weeks! I need to investigate the reason for all the leaks and look at getting a ceramic paddle clutch plate made up. I plan to use the existing center and have it made locally.

    jim
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    and also.. at the interface where the driveshaft comes out of the differential - there is a black oring (see arrow) seal - is this seal important? I have usually just used RTV rubber sealant (that you can see here in orange). Can you purchase new ones of these, do they just come off or are they actually permanently attached??? Has anyone ever replaced this seal?

    I think this may be one of my main leak issues.

    that and the fact the the VC joint was not bolted up tight.. does the CV joint need a sealing gasket??

    2ndly, see burning on flywheel from slippage.. should be ok...
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    Not sure on the seals, sorry.

    Are you going to get the flywheel skimmed. You may have some judder otherwise?
    Good chance to get it lightened too but not sure how effective this is on turbo cars.

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    Quote Originally Posted by AlfaJack View Post
    Good chance to get it lightened too but not sure how effective this is on turbo cars.
    Yes, lightening the flywheel CAN have an effect on turbo cars too. You can have a quicker engine response. So will do lightening other engine parts {con rods, con rod bolts, front pulley, crankshaft ...}.

    But, do you know {or someone else} the % off to go / or the mm to remove? I'm really very interested!
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    Nick

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    Quote Originally Posted by Brul(tm) View Post
    From memory, 76 to 89 mm.

    Regards,
    Marc
    it's 67 and 77 mm. Just measured the old tube.
    Nick

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    What's this Jim? Air filter intake?
    And if so, did you have any issues with water/rain?
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    Nick

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    yes its the air filter that goes from a flexible hose to the turbo. I have not had any problems with rain or water...Any idea on my seals question?

    jim ..

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    Quote Originally Posted by arjunior45 View Post
    it's 67 and 77 mm. Just measured the old tube.
    I wonder what hose I was messuring then

    Regards,
    Marc
    In a world full of compromise...
    ...some don't.
    ___________________________
    Opel Astra Sports Tourer 110HP 2017
    Alfa 147 1.6 16V 120HP
    Alfa 155 Q4 2.0 16V turbo

  19. #19
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    Quote Originally Posted by jimnielsen View Post
    Any idea on my seals question?

    jim ..
    No idea. I have been told, long time ago, that it's a common/usuall problem that sealing but can be replaced/solved. But that's all I know.
    Nick

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    Can?t be replaced by an o'ring?

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    I think it is an unusual shape to fit inside the bolts.

    p.s. Amazing balancing act with the gearbox on the jack!

  22. #22
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    No, the rubber ring is actually round - would this 'part' be available from alfa romeo? Has anybody ever replaced it before?

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    Is that just a standard O ring Jim? It looks like it is. It definately needs to be replaced. RTV is not necessary if the O ring is good. Some rubber grease can be used to make sure it does not get damaged when the gearbox is reinstalled.

    I would just find an O ring that fits. It needs to be the right thickness of course. It does not need to be Alfa OE. I had a kit to make these O rings because dealers never seem to have these parts in stock.

    The flywheel looks fine. The clutch centre spline is common so a clutch builder should be able to supply a new comp type plate for you if you want. Get the cover uprated of course too. Who are you using to do that?

    btw you have a more equiped workshop than most mechanics!
    Last edited by SteveNZ; 18-03-10 at 00:34.

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    Thanks Steve, I live in the middle of nowhere so I need enough equipment to be able to get stuff done by myself. I will see if I can fine an o-ring as you have suggested.

    what do you think of this as a replacement clutch...

    http://cgi.ebay.com/LANCIA-DELTA-HF-...item3a58c7d113

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    Quote Originally Posted by jimnielsen View Post

    what do you think of this as a replacement clutch...

    http://cgi.ebay.com/LANCIA-DELTA-HF-...item3a58c7d113
    No idea but you would have to assume it's good. Notice the picture show is not a Q4 clutch

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