C02 Difficult gear enagagement or disengagement

Make: Alfa Romeo
Model: 156 Factory Service Manual
Year: 1997–2002
Section: Gear shifting › C02 Difficult gear enagagement or disengagement

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Fault diagnosisC02 Difficult gear enagagement or disengagement

C02 Difficult gear enagagement or disengagement

The engagement of the gears is sometimes difficult; there is also a noise in the area of the gearbox ("the gears grate").

Step	Test procedure	Result	Action
0	PRELIMINARY CHECKS Check that the clutch releases properly: with the engine running, press the clutch pedal and engage a gear	OK	The defect does not occur again: Move onto step 1
0		The gearbox always grates in any gear: the clutch does not disengage	Continue according to the instructions for the Move onto step (see E01)
1	CHECK GEAR SELECTION Check the condition of the gear selector ball springs (see OVERHAULING GEARBOXES Assembly 2110B)	OK	Move onto step 2
1		Springs or balls damaged	Replace the components involved End of diagnosis
1	CHECK GEAR SELECTION Check the condition of the gear selector, in particular the ball (see OVERHAULING GEARBOXES Assembly 2110B)	OK	Move onto step 2
1		Ball damaged	Replace the components involved End of diagnosis
2	CHECK SYNCHRONIZER RINGS Overhaul the gearbox (see OVERHAULING GEARBOX Assembly 2110B). In particular, check the synchronizer rings: they should not show signs of wear on the internal surfaces.	OK	Move onto step 3
2		Seals worn	Replace the synchronizers End of diagnosis
3	CHECK GEARS Overhaul the gearbox (see OVERHAULING GEARBOX Assembly 2110B). In particular, check the gear front teeth: they should not show signs of notches or excessive wear.	OK	Move onto step 4
3		Gears worn	Replace the gears involved End of diagnosis
4	CHECK HUBS AND SLIDING SLEEVES Overhaul the gearbox (see OVERHAULING GEARBOX Assembly 2110B). In particular, check the hubs and the sliding sleeves: they should not show signs of notches, wear or excessive clearance they should slide freely	OK	Move onto step 5
4		Sleeves or hubs worn	Replace the sleeves or hubs involved End of diagnosis
5	CHECK CORRECT OPERATION Check that the fault is no longer present	OK	End of diagnosis
5		Fault persists	Incorrect selection of diagnostic procedure

‹ Prev C01 Stiff gearshifting control Next › C03 Poor gear enagagement sensitivity

Parts & tools for this job For 1997 Alfa Romeo 156

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