Fanalone restoration

[ncundy]

The plain bushes on mine were fine (as was the remote shaft), I just replaced the O rings and oil seals. Looking at them they don't look that hard to push out, then make up a new set in bronze. Cue someone who has done it telling me it's worse than removing the heater 

[Dilambdaman]

[Robin; this was quite straight forward as the nut was loose on mine. Once the nut is off you can remove the flange then undo the outer retaining nuts and the bearing cartridge lifts out. It looks as though you can then split the box. I have a copy of the gearbox overhaul document for piggy back boxes, it's in italian but a picture is worth a thousand words etc. If you want a copy PM me]

Neale,

Many thanks, a copy of the document you have would be most welcome.

Jonathan is well on the way to stripping the box and has sent me some pics. I'll start a new thread detailing his efforts thus far and post the pics.

Robin.

[ncundy]

Great - love to see some photos, hope there are no nasty surprises.

[lancialulu]

Colin re remote selctor bushes

I had exactly that problem on my 1600 sport box with worn remote shift bearings. Well it had done best part of 170,000 miles....

I looked long and hard at the problem then decided the only real way was to drop the box out. It wasnt too bad (its the second time I have done it to this car - to solve the front oil seal(s) problem of oil leak onto clutch, and forth time in total). I think dropping the box is easier if you can get the car high on large axle stands and have a transmission cradle on a jack that can pitch fore/aft.

I would have done both jobs when I took the box out the first time but had only had the car for a few weeks and didnt realise how bad they were. Anyway a few months later I knew I had to do then and not having neil's lathe I saw some oems on ebay and reckoned that they would do for the next 100k's! They are made out of something like nylon... and the old ones push into the remote housing ok but then tease about getting them out of the housing afterwards!!!

Tim

[ncundy]

Remote is finished now apart from getting hold of a spring for the bottom stay arm of the selector (item 6) which was missing. It is shown as optional in the TAV but I can imagine it rattles without it.

Tim, how are they lasting?

[ncundy]

Now split the box as the two vertical selector bushes (first and second) photos are worn and will be replaced. The selector had plenty of slop in it but it's difficult to tell with the remote connected as that disguises it. When that's disconnected any wear in the selector bushes becomes apparent.

[DavidLaver]

How good can a Fulvia five speed change be?   I guess you're going to find out...

David

[lancialulu]

Neil

No6 spring is particular to the early 5 speed box you rightly have on your F'lone. Later boxes/remotes (like on mine) were different. The lower pivot was threaded into the housing and greased so just rotate on its threads - never seemed to wear but you have to be careful on reassemble as you can set the distance to set the throw of the gear lever if that makes any sense???

Tim

[ncundy]

Tim,
Yes - that makes sense.

The offending bushes are out. Simple; when the 'box is in pieces! Hopefully David, it'll be a good 'un when it's done. It'll be interesting to compare it with the four speed and the S2 five speed.

Another little detail which I like is the production quality stamp, year in the centre and the number of pips representing the months. August '69 for this box. Plenty of these all over the car in various places.

[Neil]

Neil, please check the narrow area around the stem of the ball as in the 3rd photo, on my S2 the ball snapped off!  I took the whole gearbox to Harry Manning, who had never seen that happen before (not quite the words he used!  ), we split a spare gearbox after careful checking and replaced the damaged part and put it back.  Harry reckoned the part was faulty from new and slowly a crack opened up, then turning of the newly completed M25 it decided it had enough and came off.   I will try to find the item as I am sure I still have it some where and post a picture of it.

[ncundy]

A strange failure, but a good piece of advise - thanks. It's now on the list

[ncundy]

A slow weekend this week whilst I'm waiting for the gearbox seals to arrive, but time to strip the speedo drive and dress the journals. As ever these things add to rather than deplete the "things to do list". It has about 1 mm of vertical slop in it so a new bottom thrust washer is required befor putting it back together.

[Neale]

Neil,

One thing that you might like to check whilst the box is in bits are the little tangs on the ends of the original helicoil inserts, where some threads around the remote may come straight through the casing, leaving the tang vulnerable to dropping into the works.  I assume that this is the case on your box, it certainly is on some 4 speed boxes, though I've not checked on the piggy back box and although not normally a problem, it is worth removing the tangs whilst the option is open. I've seen only actually seen loose tangs in strange places on the heads, trapped under the cam caps!  Curiously some early S2 boxes also used the course spline (5th gear end) quill shaft, should you ever need a spare, and I assume that those boxes also use the fanalone 5th gear gear carrier as well, I hope this the case as my fanalone box is in bits with several parts missing and various gears with teeth missing!

Good luck with the work, Neale Shepherd

[jono]

Hello Neil

Our Fanelone gearbox is now fully stripped, and what a mess. It's obviously overheated causing first and second gear to weld the bearing faces to the shaft.
We finaly had the bearing faces cut off and then the gear pressed off.
The main pinion was so badly worn the teeth were razor sharp, and the small diff shaft that holds what I believe to be the planet gears, had worn so much it had 3 mm side play in the diff housing it sits in. Again this shaft had to be cut out with a grinder to remove it.
Al the bronze bushes, and syncros are badly worn and I am going through all the bearings.
A big job so far.
Thanks for the info on disc.

[fay66]

Hello Neil

Our Fanelone gearbox is now fully stripped, and what a mess. It's obviously overheated causing first and second gear to weld the bearing faces to the shaft.
We finaly had the bearing faces cut off and then the gear pressed off.
The main pinion was so badly worn the teeth were razor sharp, and the small diff shaft that holds what I believe to be the planet gears, had worn so much it had 3 mm side play in the diff housing it sits in. Again this shaft had to be cut out with a grinder to remove it.
Al the bronze bushes, and syncros are badly worn and I am going through all the bearings.
A big job so far.
Thanks for the info on disc.

Hi Jon,
OUCH ,
Any photos please.
Brian
8227