[alfa] Milano clutch failure

["George Schweikle" <schweikg@xxxxxxxxxxxxx>]

Mark,

You are in luck. You can remove the remaining piece of clutch pivot pin
using the smallest size vicegrip locking pliers through the inspection hole
in the bell housing. You may  need to break loose the threads using a small
chisel against the base. Remember the old mechanic's mantra: : "lefty
loosey, righty tighty". The broken off ball piece can be located and removed
by using one of the magnets on the end of a flexible stalk that is found at
many parts stores. I also filed a hex profile onto the end of the new pin to
make it easier to install than with the two flats provided. I used the above
technique when one of our Milanos had the clutch pivot pin break three
times. Every broken pin had the same fracture pattern, and I finally
determined the clutch fork had some forging flash that was causing a false
pivot where it contacted part of the throwout bearing, resulting in a
sideways force on the clutch pin. A little grinding removed the offending
protrusion, and the pivot pin caused no further trouble while we owned the
car.

If you look at a new pin, you will see evidence of induction hardening
around the ball area which is also where they fail. I suspect that out of
specification variations of this process are what cause failures. I always
used a new pin out of necessity, but a used one that has lasted in use may
actually be better than an a new pin.

A final note; during our clutch pin saga, my wife brought the car home one
day stating the clutch pedal actuation felt funny. Quickly jacking up the
car to peer inside the bell housing, I found that the pivot pin had
partially unscrewed itself. Using the hex end I had previously filed onto
the end of the pin, I laid on my back under the car and screwed the pin in
using a box end  wrench. However, I did this by feel only, and was most
chagrined to finally look into the bell housing and find I had
cross-threaded the pin. What could have been a minor procedure became major
when I had to disassemble a lot of parts to access the transmission end to
drill out the clutch pin threads and install a heli-coil.

Good luck,

George Schweikle
Lexington, KY
No more Milanos, just a couple of Spiders

>
> Date: Wed, 17 Dec 2003 23:29:16 -0500
> From: Mark Denovich <mark@domain.elided>
> Subject: [alfa] Jinxed.   Milano clutch failure
>
> What is this, 3 whole days after I said I had faith in my Milano?
>
> The story:  Driving home, as I was passing the last exit before the
> tunnel (2 miles away) I hear the traffic report (1 day after installing
> the radio) telling me to avoid the tunnel as there was a fatal accident
> on the other side and the tunnel was closed.  100yds farther I was in
> bumper to bumper traffic.  I inched along for a few minutes.  Then when
> pushing on the clutch... "wham" the pedal hit the floor and the car
> lurched forward.  I bumped it into neutral and rolled to the minimal
> shoulder.  I called AAA for a tow, but knew it would be a while as the
> traffic was barely moving.   Fortunately, a PennDOT towtruck was only a
> short distance behind me, and he picked me up to get my car out of
> traffic.  At least the truck was warm and I had someone to talk to, as
> it took 2 hours to get to the tunnel exit where he dropped me off.   I
> then killed some time in a Starbucks waiting for another AAA truck to
> tow me the last mile or two home.
>
> The diagnosis:  I had guessed the cluch fork broke (as happens on the
> 105 series cars, right?)  Luckily, I have a spare gearbox to compare,
> and I found that the "spherical pin" snapped off.   I heard it clunk to
> the bottom of the gearbox when I pulled the clutch fork.
>
> The repair:  It looks like I can just remove what's left of the old one
> and transplant the good pin in from my old gearbox?   Is it going to be
> that easy?
>
> - --Mark
> The Alfa Wiki: http://alfa.denovich.org
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