Alfa Romeo Repair: rear main seal replacement, air impact wrench, clutch alignment tool


Question
Hey DAve,

I'm thinking of replacing the rear main seal on my '74 GTV myself, and I know I have to drop the transmission to do that.  Is that a job that requires any special tools and/or can you recommend a good manual?  I love working on the car and have done some repairs (including replacement of clutch master and slave, fuel injector, alternator.)  Also, the differential howls quite a bit at about 4000 rpm, any suggestions?Thanks.

Answer
Hi Barrett,

It's not too difficult a job.  The only special tool I can think of that would make the job easier is a clutch alignment tool.  You can usually get away with a universal one from any autoparts store.
Of course, you have to remove the transmission and clutch and flywheel.  It would help a great deal if you had an electric or air impact wrench for the flywheel bolts.  You really should torque them properly when you re-install the flywheel, also.
The seal can be removed with a seal removing tool or very carefully with a screwdriver.  There is a driver for the new seal, but if you are very careful you can tap it in with a soft drift and mallet.
It's not easy to polish the seal surface on the crank while it's in the engine, but you should inspect it for deep grooving or wear.

I assume your rearend is only howling at 4000 in high gear.  If it's howling at 4000 rpm in every gear, then it's NOT your rear end that is the problem.
Try a synthetic lubricant in your rear end.  The howling is not really a problem.  I've driven cars for years with a rear that was very noisy.  If it gets progressively worse then there might be a problem with a bearing or something else.  I wouldn't recommend rebuilding unless you can't find another one in your area.  Even if it's a Carrier bearing or Pinion bearing that's bad, by now the gears are worn and it will howl even after you replace the bearings.
If it's not getting any worse, don't worry about it.  Race cars make all sorts of gear noises.  Just tell yourself it's a race car. :)
To tell you the truth, I haven't looked for any manuals for quite some time.  I have shop manuals on most Alfa's and never have needed to go out and find one in the aftermarket.  If you are a member of the Alfa Romeo Owner's Club, they might be able to steer you in the right direction.  If you are not a member, you might want to think about it.  The magazine is worth the membership.
There are some CD ROM disks called "Cardisk" that you might want to look into.  I have never used them but I understand they are very good.

If you try your seal change and get stuck, send me a note.

dave