International Lancia Forums

It looks like I will be up for a gearbox rebuild on my Fulvia Rallye 1.3 coupe (series 1 four speed).

The selector arm mechanism is "floating around" where it goes into the gearbox case, indicating worn bushes or broken/dislodged selctor rod. (I can not select any forward gears). The synchros are also in need of attention.

I have recently rebuilt a gearbox (not Lancia) and was thinking of tackling this one myself. Has anyone done a Fulvia gearbox rebuild themselves and can offer any useful tips etc.? Any special tools required?

I understand that the synchros are no longer available and the old ones must be rejuvinated - what is the best method here? Is it the same story with the gasket kits?

(I have removed the gear lever selector mechanism and cleaned and lubricated it, but still no forward gears... so it looks like open-heart surgery is required for the gearbox).

Any tips and advice would be most appreciated on rebuilding. And anything I should look to replace or check while it is all apart?

Thanks in advance

Mike

The Fulvia gearbox is a marvel in some ways and as is well know they seldom give trouble. Unfortunately they are far too heavy.

After removing the quill shaft and bellhousing, you can split the gearbox by removing the output flanges, speedo drive (big circlip) and all the bolts that are fitted - not the position of the dowel bolts and the copper washers. You can see the whole thing working in one half of the casing.

The need for special tools is determined by the extent of the job. If you intend to replace the synchros you will need an appropriate "clam shell" bearing puller; the bearings are a tight fit. Several of the clamping nuts are the familiar castellated type so beloved of Lancia; these can be removed by careful use of a hammer and punch. There should be no need to remove the final drive and diff assembly from the casing but if you do there is a LH threaded nut to undo - again castellated.

Try Cavalitto for the gaskets and synchros; he may have bearings too although it is rare to need these.

To refit the bearings, boil them in oil (!) and they will drop on beautifully.

When re-assembling note that there is a precise official order for tightening the bolts - I don't have this for a four speed. Apply a little non-hardening sealant (blue) between the faces only at the bottom of the 'box on re-assembly.

Best of luck

Paul