Transmission

Supplement: Revisions and information on later models / Transmission

PART A:
1301 CC TURBO IE ENGINE
Description
1 The transmission is of five-speed type, based on that used in the Fiat Strada 105 TC.

2 For all practical purposes, the operations described in Chapter 6 apply, but observe the following differences.

Gearchange linkage -
removal and refitting
3 This is of two-rod type.

4 Remove the gaiter and disconnect the rods at the gear lever end as described in Chapter 6, Section 3.

5 Disconnect the rods at the transmission end by unscrewing the nuts and bolts which connect the linkage rods to the selector rods (photo).

12A.5 Gearchange rod connections at transmission (1301 cc Turbo ie engine)

6 Extract the spring clip which retains the end of the short link rod (photo).

12A.6 Gearchange link rod spring clip (arrowed) on the 1301 cc Turbo ie engine

Gearchange linkage
(Antiskid models) - general 7 The gearchange linkage and internal selector arrangement has been modified, as shown in Fig. 13.89.

Final drive output shafts - description and
oil seal renewal
8 The output shafts on this transmission incorporate a flange on the left-hand side, to which a coupling flange on the driveshaft is bolted. On the right-hand side, an intermediate shaft (see Section 13) is splined directly into the differential side gear.

9 A leaking oil seal may be renewed on the left-hand side of the final drive casing after first disconnecting the driveshaft. Then using two levers, prise out the flange/stub shaft against the tension of its retaining circlip.

10 Unbolt and remove the bearing cover.

When refitting the cover, make sure that the O-ring is in good condition.

11 To renew the oil seal on the right-hand side, first remove the intermediate driveshaft, and then prise the defective seal out of the final drive housing using a suitable tool.

12 Apply grease to the new seal lips before refitting the intermediate shaft or the stub shaft. Tighten all bolts to the specified torque.

PART B:
1372 CC IE AND 1372 CC
TURBO IE ENGINES
Description
1 The transmission is of five-speed type, based on that used in the FIAT Tipo. The transmission is mounted in-line with the engine and is located in the left-hand side of the engine compartment. Drive from the clutch is transferred through the input shaft and the mainshaft to the integrally-located final drive unit. The inboard end of each driveshaft locates in the differential. All helical gear clusters are in constant mesh, with the fifth gear assembly located on an intermediate plate mounted on the rear end of the gearbox.

Gear engagement is made by sliding synchromesh hubs. Gearchanges are made via a central floor-mounted gear lever.

Maintenance
2 Maintenance is limited to periodically checking the oil level, topping up as required, renewing the oil, and visually inspecting the transmission for oil leaks. The most likely source of an oil leak will be from the driveshaft seals.

Oil level - checking
3 For improved access, jack up the vehicle and support it on axle stands. Note that the vehicle must be level in order to carry out this check.

4 If the transmission is hot due to the car having been driven recently, allow it to cool before making the check; oil foams when hot and can produce a false level reading. Wipe the area around the filler plug then unscrew and remove the plug from its location in the front of the casing. The oil should be level with the base of the filler plug hole.

5 If necessary, top up with oil of the specified grade.

6 On completion refit the filler plug, wipe clean any oil spillage, then lower the car to the ground.

Oil - renewal
7 The transmission oil should ideally be drained when hot (directly after the vehicle has been used). For improved access, jack up the vehicle and support it on axle stands.

Note that the vehicle must be level to ensure a correct level reading when topping up.

8 Wipe clean the area around the filler plug on the front face of the transmission casing, then unscrew and remove the plug.

9 Position a suitable container underneath the drain plug (located at the left-hand end of the transmission). Unscrew the plug and allow the oil to drain into the container. Oil will start to drain before the plug is fully withdrawn so take precautions against scalding. Wait about ten minutes to allow the oil to drain fully.

10 When the oil has finished draining, clean around the threads of the drain plug and its location in the transmission casing, then refit the plug and tighten it.

11 Refill the transmission with the specified quantity and grade of oil through the filler/lever plug hole. With the vehicle level and the transmission cold check the oil level as described above, then refit and tighten the plug. Lower the vehicle to complete.

Gearlever and linkages - general 12 The component parts of the gearchange and selector assemblies are shown in Figs. 13.91 and 13.92. They do not normally require maintenance other than general inspection for wear in the linkage joints. If excessive wear is found in any of the joints, they can be individually detached and renewed.

13 Access to the control rods is eased by detaching and lowering the exhaust system from the exhaust manifold.

14 If a new adjustable control rod is to be fitted, remove the original rod as a unit, but do not alter its adjustment for length. The new rod can then (if required) be set to the same length as the original in order to maintain the original setting. Do so by loosening off the locknut and turning the balljoint as required; ensure that the angle of the joint is correct before tightening the locknut.

15 Access to the gear lever/main connecting rod joint from above is made by prising back the gear lever gaiter from the centre console.

Access from underneath can be made by raising and supporting the car on axle stands.

Working from the underside of the lever, undo the retaining nuts and remove the inspection plate from the floor (photos).

12B.15A Gear lever connection to the main connecting rod on the 1372 cc engine

12B.15B Access cover to gear lever lower connection to rod on the 1372 cc engine

16 Any adjustment to the gear linkage should be entrusted to a FIAT dealer.

Transmission -
removal and refitting
17 The transmission can be removed together with the engine and then separated as described in Section 7, or on its own (as described below), leaving the engine in position in the car. Before starting to remove the transmission, it should be noted that suitable equipment will be required to support the engine during this procedure.

18 Disconnect the battery negative lead.

19 Remove the bonnet as described in Chapter 12.

20 Refer to Section 11 in this Chapter for details and detach the clutch operating cylinder together with its mounting bracket from the top of the transmission, but do not disconnect the hydraulic fluid hose from the cylinder connection. Leave the cylinder attached to the bracket. Tie the cylinder and bracket up to support them out of the way.

21 Reaching down between the transmission and the bulkhead, unscrew the knurled retaining nut and withdraw the speedometer cable from the transmission.

22 Remove the front roadwheel trims, then loosen off the front wheel retaining bolts.

Raise the vehicle and support it on axle stands at a suitable height to allow working underneath and eventual transmission removal from under the front end.

23 Drain the transmission oil as described previously in this Section.

24 Disconnect and remove the starter motor (photos).

12B.24A Starter motor electrical connection . . .

12B.24B . . . and retaining bolts (arrowed) on the 1372 cc ie engine

25 Detach the reversing light switch lead connector.

26 Undo the retaining bolt and detach the earth lead from the rear end of the transmission (see photo 7C.33). Refit the bolt once the lead has been disconnected.

27 The engine must now be supported at its left-hand end. If the engine/transmission lift bracket is unbolted it can be attached at another suitable position on the engine and the lift sling/tool attached to it, but take care not to attach it to a weak fixing point.

28 The engine will need to be supported using an engine lift beam/support bar of the type shown in Fig. 13.93. A strong wood or metal beam resting on blocks in the front wing drain channels will suffice, or alternatively use an engine lift hoist and sling.

29 Refer to Section 13 in this Chapter and Section 2 in Chapter 7 for details and remove the front driveshaft each side.

30 Prise back the tabs of the retaining washers, then undo the retaining nuts and detach the exhaust downpipe from the manifold. Detach the exhaust mounting bracket (where applicable) and lower the exhaust to allow access to the gearchange linkages.

31 Disconnect the gearchange control and selector link rod balljoints (photo). Do not alter their lengths or the adjustment setting will be affected.

12B.31 Gear control and selector link rod joints

32 Using a small diameter pin punch, drive the retaining pins from the retaining clips which secure the left-hand side underwing shield.

Prise free the clips and detach the shield.

33 Undo the retaining bolts and remove the lower cover plate from the flywheel housing (photo).

12B.33 Lower cover plate and retaining bolts (arrowed)

34 Position a trolley jack under the transmission with an interposed block of wood to protect the casing and spread the load. Raise the jack to support the weight of the transmission.

35 Check that the weight of the engine is securely supported, then unbolt and detach the front engine mounting unit, then the rear engine mounting unit.

36 Unscrew and remove the remaining bolts securing the transmission to the engine. As they are removed, note the position of any brackets or additional fixings secured by these bolts (photo).

12B.36 Transmission upper retaining bolts. Note bracket under the left-hand bolt

37 Check around the transmission to ensure that all fixings are detached from it and out of the way, then carefully pull the transmission free from the engine dowel pins. If possible engage the aid of an assistant to help in guiding or lowering the unit as it is removed.

As the unit is withdrawn from the engine, take care not to place any strain on the input shaft.

Once the input shaft is clear of the clutch, the transmission can be lowered and manoeuvred from underneath the car. If available, lower the unit onto a suitable crawler board to ease its withdrawal from under the front end of the car.

38 Dismantling and overhaul of this transmission is not recommended. If the transmission has covered a high mileage it is likely that several internal components are in need of renewal. The cumulative cost of renewing all worn and defective components will almost certainly make overhaul uneconomical when compared with the cost of a new or service exchange transmission from a FIAT dealer or transmission specialist.

39 Refitting is a reversal of the removal procedure, but note the following special points.

a) Ensure that the engine and transmission mating surfaces and the dowel pins are clean and that all clutch components are in good condition.

b) Apply a thin smear of molybdenum disulphide grease to the splines of the input shaft. Do not over-lubricate though or the grease may work its way onto the clutch friction surfaces and cause clutch slip.

c) Raise the transmission so that it is in-line with the engine, engage the end of the input shaft into the clutch driven plate hub and align the splines of each to enable the transmission to be pushed home. It may well be necessary to turn the flywheel a fraction so that the splines align for re-engagement
d) Do not fully tighten the engine and transmission retaining bolts until all are attached.

e) Tighten all retaining bolts and nuts of the specified torque wrench settings (where given).

f) Refer to Section 13 in this Chapter for details on refitting the driveshafts.

g) Refill the transmission with the specified quantity and grade of oil before lowering the car to the ground (see paragraph 11).

PART C: 999 CC AND
1108 CC WITH C514 TYPE
TRANSMISSIONS
Description
1 A new 5-speed transmission was introduced to selected models during 1992.

Identified by the way reverse gear is engaged.

The gear knob needs to pressed downwards whilst pushing the lever to the extreme right.

2 The new design includes control cables as well as rods for gear selection, see Fig. 13.94.

Maintenance
3 At the time of writing, no maintenance instructions were available, however should selecting gears become difficult, check the following.

4 The gear lever should rest vertically in neutral. If it does not, alter the gear selector adjustable rod, as appropriate.

5 Whilst turning the adjustment nut, counterhold with a 10 mm open ended spanner, located in the notch built into the sleeve. Refer to Fig. 13.95.

Fig. 13.89 Gearchange control linkage on the 1301 cc Turbo ie model with Antiskid (Sec 12)

Fig. 13.90 Exploded view of the transmission unit fitted to 1372 cc models (Sec 12)

Fig. 13.91 Exploded view of the gear selector lever, rod and linkage components on 1372 cc models (Sec 12)

Fig. 13.92 Exploded view of the gear selector and control road assembly components fitted to 1372 cc models (Sec 12)

Fig. 13.93 FIAT lift beam/support bar in place to support the weight of the engine. Inset shows lift hook engagement point - 1372 cc models (Sec 12)

Fig. 13.94 C514 type 5-speed transmission

Fig. 13.95 Gear selector adjustable rod (C514 type transmissions)

A Adjusting nut
B Location of notch in outer sleeve