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Alfa Romeo GT Factory Service Manual (2003-2010)22 · Fault diagnosis

22 · Diagnostics

Gearbox/differential oil leaks

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Consumption /leaks/ wear › Gearbox/differential oil leaks

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Fault diagnosisGearbox/differential oil leaks

GEARBOX/DIFFERENTIAL OIL LEAKS

2.0 JTS, 3.2 V6, 1.9 JTD 16V

An oil leak is seen from the gearbox/differential

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Check whether the fault is accompanied by a noise from the gearbox with the vehicle stationary and in neutral Check the gearbox/differential fluid level Op. Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY	Continue to Step 1	Noise detected from the gearbox	Continue according to the instructions in See table See table S22 NOISE'' GEARBOX / IN NEUTRAL
		Continue to Step 1	Fluid level not correct	Restore the correct level Op. Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY . If the defect persists, Continue to Step 1
1	LEAKS CHECK	All OK	Problems met	Operation
	Thoroughly wash the gearbox, cover it with talc and road test the vehicle. Visually check that there are no leaks In particular, check the condition of the gaskets: Gearbox input shaft gasket; Rear cover gasket; Differential oil seal	Continue to Step 2	Leaks from the seals	Replace the gaskets Op. Op. 2110C22 GEAR INPUT SHAFT SEALS - R R
			Left differential flange leaks	Replace the flange Op. Op. 2110D53 LEFT HAND FLANGE ON DIFFERENTIAL - R+R
			Right differential oil seal leaks	Replace the oil seal Op. Op. 2110D63 RH DIFFERENTIAL SHAFT OIL SEAL - R R
2.0 JTS 3.2 V6 1.9 JTD 16V Smart gearbox	Thoroughly wash the gearbox, cover it with talc and road test the vehicle. Visually check that there are no leaks In particular, check the condition of the gaskets: Gearbox input shaft gasket; Rear cover gasket; Differential oil seal	Continue to Step 2	Leaks from the seals	Replace the gaskets Op. 2110C24
			Left differential flange leaks	Replace the flange Op. Op. 2110D53 LEFT HAND FLANGE ON DIFFERENTIAL - R+R
			Right differential oil seal leaks	Replace the oil seal Op. Op. 2110D63 RH DIFFERENTIAL SHAFT OIL SEAL - R R
2	GEARBOX CASING CHECK	All OK	Problems met	Operation
1.9 JTD 16V 3.2 V6	Visually check the condition of the gearbox casing, using talc	Continue to Step 3	Casing damaged, cracked or distorted	Replace the gearbox casing, the rear cover, or the entire gearbox Op. Op. 2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20
2.0 JTS	Visually check the condition of the gearbox casing, using talc	Continue to Step 3	Casing damaged, cracked or distorted	Replace the gearbox casing, the rear cover, or the entire gearbox Op. Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
3	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

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Parts & tools for this job For 2003 Alfa Romeo GT

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