Good day Gents,
Needing some advice on a S2 gearbox. The gearbox last ran around 15 years ago.
After having drained the oil, the crown wheel side drain plug had some very fine metal shavings stuck which I assume is normal. The gearbox side drain plug however has what seems to be pieces of a collapsed bearing stuck on it - see photo.
I don't have experience when it comes to gearboxes and need some advice from the experts where these metal fragments could have originated from and what the best course of action is.
Any advice appreciated.
S2 Gearbox Woes...
S2 Gearbox Woes...
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Last edited by dvillijg on 15 Apr 2026, 09:58, edited 12 times in total.
Re: S2 Gearbox Woes...
I bet it is the cage of one of the ball bearings.
I have an S 2 gearbox with overhauled. All new bearings but the case is slightly bent. We could transfer all internals.
I have an S 2 gearbox with overhauled. All new bearings but the case is slightly bent. We could transfer all internals.
Re: S2 Gearbox Woes...
Thanks for the offer Huib. I am based in South Africa and if I cant source parts locally then I may need some assistance.
I finally got around to attend to the gearbox again.
On removing the gearbox rear cover it was obvious which bearing is the problem.....and indeed the bearing cage as Huib suspected. Wonder what would have caused that? Hopefully no other damage as a result of this bearing failure.
Now to find a replacement input main shaft / main drive shaft rear bearing and see how we tackle this. I have already split the gearbox and I don't see any other visible issues yet...
Whilst I have the gearbox open what else would be maintenance checks on a 54 year old gearbox? I am following this article - https://www.casalancia.nl/en/gearbox which is great but overall there doesn't seem to be much detail on the internet when it comes to Fulvia gearboxes.
Any advice appreciated.
I finally got around to attend to the gearbox again.
On removing the gearbox rear cover it was obvious which bearing is the problem.....and indeed the bearing cage as Huib suspected. Wonder what would have caused that? Hopefully no other damage as a result of this bearing failure.
Now to find a replacement input main shaft / main drive shaft rear bearing and see how we tackle this. I have already split the gearbox and I don't see any other visible issues yet...
Whilst I have the gearbox open what else would be maintenance checks on a 54 year old gearbox? I am following this article - https://www.casalancia.nl/en/gearbox which is great but overall there doesn't seem to be much detail on the internet when it comes to Fulvia gearboxes.
Any advice appreciated.
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Last edited by dvillijg on 15 Apr 2026, 12:33, edited 1 time in total.
Re: S2 Gearbox Woes...
Several things.
Your reference to a page on www.casalancia.nl.
I own both this forum and casalancia.nl. This forum is to ask questions and help each other with help and information. Casa Lancia is a commercial company where one can bring his or her Lancia and we fix it whether it is service, repair, complete restoration (body and technical) or whatever. I try to keep those two worlds apart.
What I would do in any case is replace the oil seals, the needle bearing at the input, the bronze bushes for the yoke. The latter wear and the gearbox throws out oil over the top. Then check the bearings, measure the clearance on the synchro rings. Replace bad parts. Clearances and instructions are in the DT book and the workshop manuals.
The two flanges at the side are fastened to the half axles with two low quality M6 bolts. If there is play on the splines the M6 bolts may break. They are not strong enough to transfer all the horsepower of the engine. Debris may go inside the CVJ which causes vibration. Vibration causes metal fatigue and destroys rubber. If one of the rubber buffers between upper wishbone and front spring is lower than the other one, you most likely had excessive vibration on the side where it is lower and wing and inner wheel arch may also be tearing.
At Casa Lancia we modify the fastening. We make a new steel disc with a groove for an O ring and use 12.9 Allen key bolts (with O rings under the heads). They can be locked by drilling holes in the head and put a steel wire through the holes.
Your reference to a page on www.casalancia.nl.
I own both this forum and casalancia.nl. This forum is to ask questions and help each other with help and information. Casa Lancia is a commercial company where one can bring his or her Lancia and we fix it whether it is service, repair, complete restoration (body and technical) or whatever. I try to keep those two worlds apart.
What I would do in any case is replace the oil seals, the needle bearing at the input, the bronze bushes for the yoke. The latter wear and the gearbox throws out oil over the top. Then check the bearings, measure the clearance on the synchro rings. Replace bad parts. Clearances and instructions are in the DT book and the workshop manuals.
The two flanges at the side are fastened to the half axles with two low quality M6 bolts. If there is play on the splines the M6 bolts may break. They are not strong enough to transfer all the horsepower of the engine. Debris may go inside the CVJ which causes vibration. Vibration causes metal fatigue and destroys rubber. If one of the rubber buffers between upper wishbone and front spring is lower than the other one, you most likely had excessive vibration on the side where it is lower and wing and inner wheel arch may also be tearing.
At Casa Lancia we modify the fastening. We make a new steel disc with a groove for an O ring and use 12.9 Allen key bolts (with O rings under the heads). They can be locked by drilling holes in the head and put a steel wire through the holes.
Re: S2 Gearbox Woes...
Ah. And about parts. Isn't Felix Furtak in Cape Town able to supply parts?
Re: S2 Gearbox Woes...
Dear Huib,
many thanks for the advice. I will check all items you pointed out.
I have reached out to Felix and currently awaiting his feedback on parts. I know there are 2nd hand ones readily available but a new one we may need to get from overseas.
Regards
many thanks for the advice. I will check all items you pointed out.
I have reached out to Felix and currently awaiting his feedback on parts. I know there are 2nd hand ones readily available but a new one we may need to get from overseas.
Regards