22 · Diagnostics

Gear engagement or release difficult

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Gear shift › Gear engagement or release difficult

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Fault diagnosisGear engagement or release difficult

GEAR ENGAGEMENT OR RELEASE DIFFICULT

The engagement of the gears is difficult; there is also noise in the gearbox area (the gearbox grates)

1	CLUTCH CHECK	All OK	Problems met	Operation
		Results of the tests
	Check with the engine running and the car stopped that there is no noise (grating gearbox) when all the gears are engaged.	Continue to Step 2	The gearbox grates on all gears	Continue according to the instructions in See table See table E01 CLUTCH NOT RELEASING CORRECTLY
		Continue to Step 2	The gearbox does not grate on all the gears (only some of them)	Continue to Step 2
2	CHECK CONDITION OF GEARBOX	All OK	Problems met	Operation
2.0 JTS		Continue to Step 3	Pre-synchronizers damaged	Gearbox overhaul Op. Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
			Synchronizers damaged or worn	Gearbox overhaul Op. Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
			Gears worn	Gearbox overhaul Op. Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
			Sleeves or hubs worn	Gearbox overhaul Op. Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REBUILD - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS
1.9 JTD 16V 3.2 V6		Continue to Step 3	Pre-synchronizers damaged	Gearbox overhaul Op. Op. 2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20
			Synchronizers damaged or worn	Gearbox overhaul Op. Op. 2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20
			Gears worn	Gearbox overhaul Op. Op. 2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20
			Sleeves or hubs worn	Gearbox overhaul Op. Op. 2110B34 4 SPEED GEARBOX GEARS, SHAFTS AND BEARINGS - REPLACE FOLLOWING OPERATION 2110B20
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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