Found rust on the Transmission gears.

[Newbie1979Pini]

I was getting ready to drop the tranny to start a rebuild (because 4th gear was jumping out into neutral), so I drained the oil, and pulled the bottom plate. I expected to find chunks of metal in the sludge, but only found a little grit.
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020016_zpse1d8c269.jpg[/img][/img]
I thought the gears actually looked pretty good (to a novice who has never cracked open a transmission in his life).
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020010_zps025e43bd.jpg[/img][/img]
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020011_zpse66cc299.jpg[/img][/img]
But, upon closer inspection, I found rust on various gears and rings.
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020012_zps44e4ba1d.jpg[/img][/img]
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020013_zpscf9c5c57.jpg[/img][/img]
[img][IMG]http://i28.photobucket.com/albums/c229/helgamya/P1020014_zps115e0dcf.jpg[/img][/img]
Can these be cleaned up, or would I be doing more damage than good?

[htchevyii]

That seems pretty odd to me, must have sat for a very long time or something. Most of the rust that I saw looked like it was on parts that would not matter, ( not on gears that mesh, etc), but if the bearings got rusty you will have problems.

[vandor]

You will have to take the trans apart anyways to fit 4th gear. Just inspect all the bearings and the gear teeth on each gear.
If any of those has pitting from rust, then you should replace it.

[Newbie1979Pini]

Well, the transmission is out. I can only do a little at a time after work. I'll start the tear down tomorrow. Anyone in the Phoenix area know of a local source for these transmission parts and or gaskets?
I have a box of what looks like used gears, but a few of them are questionable. I could order from "International Auto Parts", but why ship if I can get it local.

[wizard124]

I just did mine. Go here for some info if you haven't done so: http://fiatspider.com/f08/viewtopic.php?f=9&t=26031

Your tranny doesn't look so bad. There is rust on the cup(s) that holds the syncro spring. Rust on the outside of the shift sleeves. Should be easy to emery cloth those clean. One of the shift forks looks like it is well worn, those are available.

Sleeves, syncros, gears, bearings need to be inspected closely once disassembled. You know that 4th is a problem so focus there.

Before you completely tear it apart, re-assemble the shifter and shift extension. With the access plate removed, shift through the gears. the tranny should hold each gear without it popping out. If it doesn't hold 4th, I am thinking it is a bent/worn shift fork (not fully engaging 4th gear), or a detent dowel or spring is bad or missing. Popping out under load, other issues can come into play.

[Newbie1979Pini]

"Before you completely tear it apart, re-assemble the shifter and shift extension. With the access plate removed, shift through the gears. the tranny should hold each gear without it popping out. If it doesn't hold 4th, I am thinking it is a bent/worn shift fork (not fully engaging 4th gear), or a detent dowel or spring is bad or missing. Popping out under load, other issues can come into play."

The transmission is out. When you say to shift through the gears - you mean to hand spin it through the gears? I was going to start the tear down today, but the "clutch release bearing" has me stymied. The Clymer manual I'm copying from the library just says "detach the release bearing from the release fork and take it out." All I can think is HOW???

[wizard124]

"Before you completely tear it apart, re-assemble the shifter and shift extension. With the access plate removed, shift through the gears. the tranny should hold each gear without it popping out. If it doesn't hold 4th, I am thinking it is a bent/worn shift fork (not fully engaging 4th gear), or a detent dowel or spring is bad or missing. Popping out under load, other issues can come into play."

The transmission is out. When you say to shift through the gears - you mean to hand spin it through the gears? I was going to start the tear down today, but the "clutch release bearing" has me stymied. The Clymer manual I'm copying from the library just says "detach the release bearing from the release fork and take it out." All I can think is HOW???

Yes, shift it. You may need to hand turn the input shaft slightly. Does 4th gear engage and hold?
Pull the the clutch release lever, it should pop out of the pivot bolt. Then work the release bearing loose.

[vandor]

Why shift through the gears if the trans is going to be torn down and inspected it anyways? Nothing beats actually looking at the parts

Very unlikely you will find the parts locally, unless you have a shop specializing in Fiats there. We carry all the parts and likely are cheaper than International.

[Newbie1979Pini]

"Newbie" describes me well. I got the release bearing off without any special tools. It is held in place by the clutch cable lever. I pulled the lever away from the shaft from outside the transmission and it disconnected from the bearing. Too simple. I marvel in my ignorance, and am disappointed in the tech manuals I've been searching through because the all just say "remove the bearing" without an explanation of how.

I did try the gears an 4th & 5th sounded a little more 'metallic'. The tear down has begun, and I'll be posting pictures of questionable items along the way. I especially need to know about the electrical connections (what do they do, are they vital to the working of the transmission), because mine only had one wire, and that grounded to the transmission body. It's late and I work really early, so I'll post more tomorrow.

[Newbie1979Pini]

"I especially need to know about the electrical connections (what do they do, are they vital to the working of the transmission), because mine only had one wire, and that grounded to the transmission body.

[img[/img]
I have a picture of the side electrical connection having two wires - one to the ground and one to the rear electrical connection - what does the rear electrical connection do?
[/img]
I can solder a second wire to the side connection, and run it to the rear, but what connects to the second connection on the rear electrical?
[/img]

[bradartigue]

The only electrical switch you need in the transmission or gear shifting assembly is the reverse light switch. The other ones are for the high throttle assembly, if you still have it and want to use it please say so and we'll help you get it working. If you're not using the stock carburetor and manifold or intend to switch to a different carburetor setup then you can leave these connections alone.