SHOP MANUAL @™ PROPELLER SHAFT REAR AXLE AND SUSPENSION @ GIULIA 1300 Ml GIULIA 1300 ti Ml GIULIA TI SUPER Ml GIULIA SPRINT GT Ml GIULIA GTC MW GIULIA Tl M@ GIULIA SUPER Ml GIULIA SPRINT GT VELOCE M SPIDER 1600 &Manual, supplied to all authorised ALFA ROMEO Repair Shops contains instructions for the servicing, overhaul and re- Ccongitioning of the following chassis components: propeller shaft, suspensions and rear axle, steering system of GIULIA Models. ‘The operations are amply illustrated so that the detail and unit concerned can be quickly identified and the tools to be used land the correct method of operation can be seen. Only genuine ALFA ROMEO spares should be used if any assem- biies or parts have to be replaced: only in thie way can complete interchangeability and fully satistactory performance be guaran- teed. It is also recommended that, for all overhaul and reconditioning works, the suitable special tools be used. ‘This Manust should be kept continuously up-to-date by the addition fof new information and instructions issued at intervals by the Technical Servi regular ~ Information Sheets ~ and Modifica ‘ons » which snould be copied on to the blank pages at the end of the handbook vision in th n Instus ALFA Ce ROMEO Fe Coe red Direzione service AssistenzaCONTENTS PROPELLER SHAFT 1 amoral fom car ~ Disessembiy | snapection and checking 53 Reastembiy 10. Raassombly - Rlnsalation REAR AXLE ANO SUSPENSION 12 Genera), 13 Cutaway vow Inspection and cnacking 2a. Reassemb'y on bench Suspension springs 2 aSERVICING INSTRUCTIONS When disassembling and reassembling always use the correct wrenches, extractors and tools (standard and special) to avoid damage to parts To loosen close-fiting steal parts lightly tap with a copper or aluminum matiet; for light alloy parts (covers, housings, etc.) use ‘a wooden or plasti¢ mallet, ‘when gisassembling check that specially coupled parts are stamped with the correct number or reference mark; any original parts (previously replaced) found unmarked should be so stamped, Components of ditferent assemblies should be kept separate and huts should be loosely screwed onto their original studs or bolts Before washing parts, brush or wipe off the thickest grime (to avoid soiling the solvent in the washing tank), then wash with paraffin or hot water and soda and remove any remaining dirt with compressed air; dry all parts immediately alter washing so that they do not rust. Deformed parts must be trued with the use of a hydraulic press or some other suitable means of applying pressure; hammering reduces machanical strength and should be strictly avoided After parts have been ground or honed, wash them thoroughly and blow the parts with compressed air in order to remove all traces of emery powder. When reassembling, clean components (particularly after regrind- ing) with compressed air or a clean dty brush. when reassembling lubricate all mechanical parts properly (except ‘carbon bushings) to prevent seizing and scoring when the engine is first run Use a brush and absolutely clean oi 10 apply a film of oil to all parts which have to be lubricated on reassembly; the brush, the fll and its container, should be kept completely free from dust ‘and should be used for the above purpose only. With adhesive paper or clean rags mask out those parts of the engine remained uncovered after disassembling to prevent dust of foreign matter from entering them. When reassembling, renew all gaskets, oil sealing rings, spring washers, tabwashers, safety plates, locknuts and any components rot in pertect condition. Use always genuine ALFA ROMEO spares.GIULIA 1300 GIULIA 1300 ti GIULIA TI GIULIA TI SUPER GIULIA SUPER GIULIA SPRINT GT GIULIA SPRINT GT VELOCE GIULIA GTC SPIDER 1600PROPELLER SHAFTPROPELLER SHAFT GEARBOX DIFFERENTIAL, LePROPELLER SHAFT REMOVAL FROM CAR - DISASSEMBLY center cross-member 1 the par © Take the propeller shait away as a unit si reassembly; loosen bolts 3 andPROPELLER SHAFT INSPECTION AND CHECKING A 998 Hao om FRONT SECTION © Check rubber collar 13 and components A of bearing assembly for sound conditions; replace damaged parts. © Check felt 12: replace it, if necessary. '* ‘Check rubber coupling 11 for damage or distortion; replace it, if necessary, REAR SECTION © Check the run-out € of shaft rear section ava and B: — max. run-out at A= 4 mm (.016" = max. run-out at B= .1 mm (.004") Mf run-out exceeds the above limits straighten the shaft in a hydraulic press, Hf truing isso difficult that. vibrations could take place when shat is reinstal- led, replace the shaft, IF so, the whole shaft must be rebal- ‘anced dynamically. © Check the splines in the shaft and sti Ing yoke for good appearance: check that grease fittings on yoke and U-joints are not obstructed, © Check yoke felt gasket: if damaged eplace ‘t © Check that play G between spline: follows: factory setting 04 mm 0016") wear limit 2 mm (0078")PROPELLER SHAFT REASSEMBLY © Install the ball bearing in its seat and stake in place with @ suitable punch to prevent any axial movement of the bear- ing. © Reassemble the front section of shatt in the following sequence: * the bearing spacer 14 + the linger 15; + the bearing seat and rubber collar as- semby 16; + the siinger 8: + the slinger spring 7; + the keys 6: + the yoke 1 according to the alignment marks. Tighten nut and palnut © Connect yoke 2 and rear shaft according to alignment marks. © Join together front and rear sections of shaft according to alignment marks praviously made, © Place the rubber coupling 11 on front shaft yoke with the aid of the too! *A.2.0124; tne mounting bolts should be billed to prevent them from binding in the Bushing when being locked © Torque the nuts on mounting bolts to 4-45 Kgm, (926-397 Ib. it) with too! as.0162,PROPELLER SHAFT REASSEMBLY - REINSTALLATION Note - if 2 suitable balancing machine is available, dynamically balance the shaft assembly (Max. out of balance 42 gr. cm: = test speed 5000 rpm) The dynamic balancing is essential when any component of shaft has been replaced. It the propeller shat of balance, apply balance weighs in the proper positions. is out © Aeinsiall the propeller shaft assembly as follows: * pack the bushing for centering prop. shaft and gearbox output shatt. with grease (about 1/2 cc) AGIP FA GREASE 15 - SHELL RETINAX G + Connect shatt yoke to differential yoke according to alignment marks. prev ously made: * torgue the nuts of connecting bolts to 35-4 Kgm (253-289 Ibs) with tool A062. + Mount the rubber coupling onto the gearbox yoke with the aid of the tool 2.0124; the mounting bolts. should be oiled to prevent them from binging in the bushing when being locked Torque the nuts to 45-55 Kgm (32.6 - 397 tbl} with too! A.5.0162. © Compicte the reinstallation of the shaft in reverse order of removal 10REAR AXLE AND SUSPENSIONREAR AXLE GENERAL The live axle is attached to the body through two rubber-bushed radius rods which counteract tractive and braking efforts longitudinally; @ trunnion reacting to transversal etforts and mounted on rubber bushings: + vertical coil springs secured to the radius rods and telescopic hydraulic shock absorbers coaxial with the springs. Upward movement of rear axle in restricted by bump- ff pads and downward by rebound straps. The aif- ferential, with the hypoid ‘inal drive. is housed in the aluminum carrier to wnich the two axle tubes enclosing the semifloating axie shatts are connected, A magnetic plug in the cattiar retains metal par- ticles suspended in tho oi OVERALL GEARBOX/REAR AXLE RATIOS 43:9 41:10 att | cael 41:8 Ast and Gear Sra ath sth Rev. GIULIA 1300 (6 speed} GIULIA 1300 ti . GIULIA TI GIULIA TI SUPER ry GIULIA SUPER GIULIA SPRINT GT GIULIA SPRINT GT Veloce GIULIA GTC SPIDER 1600 BE eencacs optional 12REAR AXLEREAR AXLE IN-CAR REPAIRS 14 Axle shalt, wheel bearings and packing replacement * Loosen the whee! nuts * Jack up the car as shown and put stands under the jack sockets. Remove the wheels and lower the Free the pad retaining plate 1 at one end only and'take the pads out * Disconnect the hand brake cable 3. * Remove the return spring 4 from both attachment points * Loosen screws § fastening the brake caliper to its bracket 6, remove the cal- iper by withdrawing the push rod from slave cylinder + Loosen screws 7 attaching the brake di 8 to wheel hub 9 and remove the dis + Unscrew nuts 10 securing the bearing housing to axle tube and remove the splash shield 11 © Witharaw the axle shaft as follows (Ret. Too! Bulletin no. 33/2}; + Install the abutment A, too! A.3.0109/1, fon axle tube: + Pass offset pins B of the tool A.3.0109, through the holes into the axle shalt flange and tighten by hand the nuts, against the plate C: * Mount the puller Das shown and witnaray the’ axe snaft by turing theREAR AXLE IN-CAR REPAIRS © i necessary, remove the axle shaft bear ing as follows: unscrew the bearing ing nut with the too! 5.0120 + mount the plate P of tool ASo109 (Toot Bulletin no, 33/2) on tne bearing ing and tighten the nuts + pass the offset pins B through the holes into the ge so thai they rest against + mount the puller D onto the shal flange making sure the screw E is pertectly centered and withdraw the shat Withdrawing the axle shafts trom cars with drum brakes + loosen tne attaching screws and remove the brake drums: + loosen the nuts fastening the shoe back plates to axle tool A.3.0109 (Too! Bulletin no. 33; ate T. 5 offset pins B of t ihyough the holes into the axle shalt flange ag Das shown and withdraw 1 mount the pull ine screw E. Inspection and check maximum run out: 10 mm 0039") Minor adjustment aig able pressREAR AXLE IN-CAR REPAIRS Reassembly © Install bearing hous ‘onto axle shaft; to ina ceed as follows (Teo! 8 engage the puller D with the brackets of plate P: the bearing can now be driven in place by turning the screw E against the end of the shaft az shown: * screw in the bearing ring nut with tool A.5.0120; + Bend the tabs of tabwasher. shaft into axle tube and start axle splines into side gear, taking are not to damage the oil seal packing and the battle in the axle tube, © Push shaft in until it bottoms by tapping with @ mallet on a punch placed in the shaft flange hol © Install the splash shielé on caliper bracket and torque the attaching nuts + 1048-55 Kgm (94.9 -327 Ib-tt] with the tool AS.0146; Secure with the pal nus © After installation, check that the axle shaft has no end play: if any play exists, take it up by inserting shims S as required between outer race of bear ing and bearing housing, in mind. that * the difference in gap A and B be. tween dise and caliper on each side should not excead 6 mm (02"): if + torque the bolts * attaching caliger Drackat to 23-28 Kgm (16.7-20.2 Ib-ttREAR AXLE REMOVAL 1 Disconneet the brake lines way union: 2 loosen bolts attaching propelier shaft 10 dilferantia rom three: and brake ‘ilferential Femove rubber hock abs Cars with drum brakes ® Hook the tool A2o1as with up to the AaREAR AXLE DISASSEMBLY ON BENCH © Place the rear axle on a suitable stand: © Remove: ‘brake caliper assemblies; + brake discs and axle shatts (refer to page 14) + axle tubes; + and disassemble the differential car- © It necessary, withdraw the bearing cups from differential carrier and. left-hand axle tube with tool A.ROTIS; take out and retain the shims, For withdrawal, set the parts upright an proceed as shown in the illustrations. © Remove final drive pinion and shaft from differential carrier as follows: * free the flange securing ring nut trom the tabwasher + install tool A.2.0148 (Too! Bulletin no. 116) onto ge with the suitable bolts to prevent the pinion trom rotat ing when unscrewing the ring nul; + insert the bushing AS.0104 (Too! Bul jelin no. 74/1) and unscrew the ring + withdraw the pinion & shait assembly from carrie by tapping with a sot mallet + slide out spacer 1 and slinger 4 3 trom differential carrier. © if necessary, withdraw the rear bearing cone with tool A.3.0150 (Tool Bulletin no. 92): for withdrawal, fit the half rings A (of the proper type} onto the pinion fand rest the parts 0 arranged against the base C; to slide aut the bearing tap lightly on pinion shaft end with a soft malictREAR AXLE DISASSEMBLY ON BENCH - INSPECTION AND CHECKING With too! A.3.0207 10/1) withdraw: 1 front bearing cup: 2 rear bearing cup. Remove and retain shims 3 (Too! Bulletin no. Differential case © i necessary, pull the bearing cones out of differential case with toa! A.3.0212 (Too! Bull tin no. 128) Loosen the screws attaching the ring gear to differontial case after then countermark and remove the Unlocking trom tabwashers ting gear from case. Drive out the shaft of differential pinions from the side opposite the key; take out pinions and side gears with their shims INSPECTION AND CHECKING a) Final drive Cheek the pinion and ring gear teeth for any sign of binding or If teeth are badly worn, replace the pinion and fing gear assembly WARNING - Pinion and ring gear are supplied as a matched set only, therefore they are net available separately. vy Check pinion bearin ditferentiat case bea of scoring, scratching, bindi sive wear’ replace them, if necessary. Ditferential pinion and side gears. (Check teeth of gears 6 and 7 for scoring dents or excessive wear Check the differential pinion shatt 8 for sign of binding or excessive wear, re- place damaged parts, if necessary. Clean all the components’ thoroughly 19REAR AXLE REASSEMBLY ON BENCH 20 Reassembling the differential case © Fit * the side gears and the shims 1 pre- viously retained: + the differential pinions and thrust washers; + the differential pinion shatt * Check that backlash between pinion and side gears does nol exceed 05 mm (.002");, if this condition is fulfilled, the gears must rotate freely by hand. To adjust the backlash, insert or re- move ‘shims 1 as required between the side gears and differential case. © Install the ring gear according to the markings previously made on differen tial case and ary torque the attaching screws to. 45-5.0 Kgm (32.5-36.1 Ib-1), © Safety lock the screws with the tab- washers. Reassembling final drive pinion © Drive rear bearing cone onto pinion shaft with the tool 4.30170, © With too! A.3.0207 (Too! Bulletin 100/) rive into their seats: 1 pinion tront bearing cup:REAR AXLE REASSEMBLY ON BENCH 2 shims 3 and pinion rear bearing cup. © Drive onto pinion shatt 1 the bearing spacer 2 the shims previously retained. © At this stage of assembly insert the Binion into differential carver ‘© Then assemble: + the front bearing cone 3 with tool 43.0168; the linger Warning: do not Install the oil seal packing,REAR AXLE REASSEMBLY ON BENCH © Assemble the flange on pinion shaft and tighten the ring nut to. 8-14 Kgm (53— 100 Ib-it): before tightening, insert bush: ing 5.0104 and prevent’ pinion from rotating with tool 20148, Checking the pre-load of pinion bearings Install the too! €.5,0100 (Too! Bulletin 190. 20/1) on the flange: + rotate the tool in both directions to settle the bearings: Position the weight in the siot marked 105 P: * check that, when leaving the tool arm {ree in horizontal position, the weight moves downward slowly through about 80 degrees. jn such @ condition the preoad is Correct and the revolving torque should be: 115-188 Kgom (10-1955 ibn) © it this is not the case, remove pinion from differential carrier ‘and change thickness of shims between spacer snd bearing cup taking in mind that = adding shims decreases the pre- Toad; — removing shims increases the pre- load, © Proceed by trial and errors until the correct prévioad is obtainedChecking and adjusting the distance of final drive pinion trom ring gear center line © The distance B from pinion top to ring gear center line should be 87 mm plus Or minus the value (in hundredths of milimeter) metal stamped on. pinion head Specifically: if this value is preceded by 1@ plus mark, the distance shall be 7 mm plus the figure stamped on pinion and viceversa. © To check proceed as follows: + withdraw the RH. bearing cup from differential carrier with too! A.30115 (see page 18) place the dummy shaft U (too! €.6.0114 See Tool Bulletin no. 27/1) in the RH. bearing seat and fasten in place by tightening nut © manually + mount a dial indicator on to the sup- port V (tool €.5.0116) and zero set the dial against the reference gauge €.6.0101 “tthe nominal dimension D=70 mm, The dimension D (70 mm) corresponds to tne distance between the pinion top surface and the generating line of ‘dummy shaft U. dummy shatt dia. 70mm = 57 mm (B) + — © Rest the dial indicator support against the pinion top anc check that the read: ings recorded (positive or negative with respect to D) are in accordance with the figure stamoed on pinion both in sign and value. © Itthis condition is not fullilled, the pinion Must be readjusted to correct assem- bly position by varying the thickness of shims § in between the rear bearing cup and'the seat in differential carrier 1dd shims to bring the pinion nearer to ring gear; — remove shims to bring the pinion farther off the ring gear. Warning: in order not to alter the pinion bearing pre-load, it is necessary also to add fof remove shims Sin between spacer and front bearing cone accordingly REAR AXLE REASSEMBLY ON BENCH ADLUSTMENT 5, = (algebraic subtraction) (= 2rd example 4 -2 +6 teas, ars example -2 +4 6 (eubiacd) sin example -s 2 = 2 (sbtrac indicator reading) minis 23 KEY TO THE FIGURE (n hundreds St mm), STAMPED ‘On BINION WHEN” FACTORY ASSEMBLED. OISTANCE BETWEEN PINION HEAD BNO AING GEAR CENTER U tanger than ominat hon by & hunt CHECKING ADJUSTMENT EXAMPLEApsustinG THE BigtANCE OF FINAL REAR AXLE REASSEMBLY ON BENCH 24 Checking the total pre-load of pinion & ring ‘gear bearings © Drive cones 1 of side bearings onto ait ferential with tool A3.0208, © Into RH. bearing seat in differential car- Fler insert: 2 shims previously retained; 3 bearing cup with tool A.3.0208, © Assemble the differential case assembly to the differential carrier © Place the cup 1 of differential carrier GH, bearing on tool €. 6.0115 (Too! Bul- letin no, 102/2); S'mount the tool so arranged on LH. flange of differential carrier and fasten with nuts + rotate handle A_until_a provisional Clearance Is obtained between pinion land ring gear. + Install the tool €.5.6100 (Too! Bulletin ‘0. 20/1) for checking the bearing pre- Jaad on pinion shaft flange; + rotate the tool in both directions to settle the bearings; + position the weight in the slot marked Y05 T and check that, when leaving the tool arm free in ‘horizontal po- sition, the weight moves downward siowly through about 30 degrees, In such a condition the total revolv- ing torque of pinion and ring gear should be: 185-245 Kgom (145-21 Ibsin). It this is not the case, rotate handle A of fool 6.0115 until the prescribes pre-load is obtained. ‘Then lock the setsorew C. ‘Note: the pre-load shall be checked in four different position of the ring gear; to do this, rotate the pinion of a complete turn after each checkChecking and adjusting the backlash of finat drive © Tighten the setscrew B (Too! Bulletin Ro. 102/2) into the drain plug boss so 8 to lock the ring gear: + have the sensing needle of a dial in- Gicator rasting against the centre plata Of too! €.5.0100 (To9! Bullatin no. 20/1) in correspondence of the reference mark 45 mm apart from inion center Tine + swing the tool in both directions and take readings of backlash on dial indicator specified value: 15-25 mm (.006- 003") This correponds to an actual back- lash at the final drive teeth of .05- 40 mm (.002-098"). Note: the backlash shall be checked in four different positions of the ring gear: to do this, rotate the pinion of a complete turn after each check and lock the ring {gear against rotation by setscrew B. © If the backlash is not as prescribed, adjust as follows: Temave the tool C.6.0115 from ditferen- tial carrier and take out the differen- tial case: age shims as required between RH. bearing cup and seat, besring in mind that moving shims decreases the backlash; xdging shims increases the back- 3h, mble the RH. bearing cup and lure to the aitfarantial carrier with the tool A.3.0208. © Reinstall tne differential case and th © Adjust screw A of tool C.6.0115 50 25 to obtain the specified bearing pre-load check th ing pee-load and check for the correc backlash. Repeat the adjustment procedure, if necessary, REAR AXLE, REASSEMBLY ON BENCH 25REAR AXLE REASSEMBLY ON BENCH Reassembling the differential ‘© Alter the pre-load and backlash are set 8 specified, It Is necessary to deter. mine the thickness of shims between LH, bearing cup and its seat. Proceed 38 follows: Femove tool €.60115 from citfeentia * withdraw the bearing cup previously fitted and, without disturbing the se A, record the dimension D with a dial indicator and the tool E (C.6.0102) as shown: * take a reading of dimension O° in the LH. axle tube. The dliference D-0', diminished by mm 002"), will give the thickness at shims fo be inserted between boating cup and the seat in the axle tube Note: the reason for decreasing the thick: ness of shims by .05 mm (.002") lies in tho fact that, while the bearing cup makes @ loose fit in tool during the measurement, in the axle tube the cup makes a press fit; as consequence, the cup shrinks. radially ‘causing @ reduction in pinion-to-ring geat clearance which eventually results in 2 greater bearing pre-load. © Install shims $ of thickness as pravious- iy determined within bearing seat in Li. aula tube: then drive the bearing cup in place with tool A.2.0208, | © Assemble the RAH. & LH. axl fasten wit . bond the tabs of tabwashe: shaft and © Again load of — if the pretoad is as specified and the backlash lower than normal, ad shims at the BiH. bearing and remove. the same thickness. irom the pack of shims. at the LH. bearing: vice- versa if the backlash is greater than normal — if the backlash is as specified and the presload is wrong, add or remove the same quantity of shims from both bearings according to whether tho pre-load must be increased or dimin- ‘shed respectively 26© Bend the tabs of tabwashers of nuts attaching axle tubes to differential car- ‘© Remove the pinion shaft flange and drive the oil ‘seal packing on pinion Shaft with tool A.3.0167; reassemble the flange and tighten the ring nut to 8-14 Kgm (58-101.2 lb-ft) with a torque wrench and the bushing AS.0104 Counteract flange rotation with tool ‘A2z01aa, © If previously removed, drive the bearing onto axle shat with too! A.3.0109; tighten the ring nut with the wrench 85.0120. © Insert the axle shaft into the tube and drive it into the differential side gear splines, © Complete the reassembly as directed on page 16 © install the rear axle assembly to tho ogy by reversing tho removal proce. ure. REAR AXLE REASSEMBLY ON BENCH - REINSTALLATION tubes | Sm aun Joss SPECIFICATION ‘Nut securing reaction trunnion te differential carrier 16 27REAR SUSPENSION ‘Suspension springing: suspension members move up and down while the car remains level. The rear suspension consists of coil springs and large diameter talescopic shack absorbers coaxial with the springs. The upward mavernent of the rear axie is limited by a rubber pad and the rebound by a fabric and rubber strap, 28REAR SUSPENSION ‘Suspension tilting: the rear axle pivots on the reaction trunnion fixed to the body while the car remains level 29REAR SUSPENSION PADS & REBOUND STRAPS - SHOCK ABSORBERS Removal of rebound straps and rubber pads © Load te rear end of car so as 10 slacken the rebound straps slightly © Romove screws and pads. taching rebound straps © Replace defective parts Note: when reassembling pads and rebound straps make sure they are in ihe same Position as before removal Removal of shock absorbers © Disconnect the shock absorbers fram radius rods © Fully collapse the shock absorbers, © From the luggage compartment remove the shock upper attachments and with draw the shocks upward: to do this, easily take away the rear seat backrest BIANCHI~ALLINQUANT oo gies Ot — ogroo: Shock absorber inspection and testing © Inspect the shock absorber barrel and the cover for distortion © Check the wer for binding against the shock abs barrel and for any sign of olf leaks. © Check that shock absorber mounting pads are in good condition and replace if n sary. © Check the shock absorbers on the test rig for correct damping action at high and low speed, 30‘© Tost as directed in Tool Bulletin no. 32/1 and specially + craw the zero raferanca lina with the fig under no load; + install the shack absorber to be tested fon the igi + turn the control knob to slow speed and start the rig motor: ine writing needle will record the corresponding then turn to high speed and record the curve. The readings should fall within the limits siven in the table below. Rear shock absorber rating: Bananas 99 lo 5x9 | 50. 040 je-190 Kal. 22a | 27 eax ining posta tas. toe | 60. a2 oe] 209 Note: shack absorbers must be tested when cool, in the event the shock has been left Inactive for a long time, cycie it through a few strokes berore testing Replace shocks with new ones if test results donot fall within the above limits. ainstall the shock absorbers by reversing the order of removal. Ingpact the mounting pads and replace, if necessary, REAR SUSPENSION SHOCK ABSORBERS Take readings with the suitable transperent chart (the enact shown is rated in Kos) 31REAR SUSPENSION REACTION TRUNNION Removal of reaction trunnion from car '* Remove the rear section of the exhaust plpe: loosen the screws attaching the trun- nion rubber bushing seats to tha body + unscrew the nut attaching the teun- sion to the pin on rear axle + swing down the trunnion and take away Inspection and replacement © Check the pads tor the attachment of trunnion to rear axle for any sign of doterioration; replace, it necessary © Chock the rubber bushings and their seats for good condition. It necessary replace them as follows * secure the flange B of the too! A.3.0163 (Tool Bulletin no. 101) to the rubber bushing seat with the three screws A, tighten screw C so as to stretch the rubber until enough gap is left to insert the half-plates E ‘when inserting the halt-plates take care to matcn the tabs F with slots | in the inner sleeve of rubber bushing | then, slacken screw C; + remove the flange B and pull the bushing and the seat out as a unit by using a suitable punch, To reinstall the rubber bushings on trun- s | nion align the reference marks on bushing | Seat and trunnion and drive the bushing with tool A.3016«, 32REAR SUSPENSION REACTION TRUNNION - SUSPENSION SPRINGS ap ing the reaction trunnion in reverse order of removal (On reinstallation check that total gap L (right side + left side) between ruber Bushing seat 1 and the plastic washers 2 does not exceed 1 mm (04"); if nec- essary, add shims § between the trun- nion beam 3 and the plastic washer: then electric weld such a shim to the trunnion. When selecting the thickness of shims to be added. keep in mind that a maximum interference fit of 1 mm: (02°) is allowed between reaction trun: hion and body. © Tighten with @ torque wrench: + the screws. attaching reaction trun- tion to, body to 48955 Kom C3 Sor oe) «the nut securing reaction trunnion to rearanie to Tie48 Kam (796-1085 1-4), Suspension springs mie oe © Remove the springs with too! A201 7 2s erected on page 17 iat. © Check the springs against the 5 aaa SBtons ger nthe able: and for any vest Sign of dlstoruon - eo 33REAR SUSPENSION RADIUS RODS Removing the radius rods © Take the spring away from the radius fod to be removed with the tool A.2.0143 a directed on page 17. © Withdraw the bolt conneeting radius rod to body and remove the rod. Inspection and replacement © Check the front and rear rubeer bush: ings of the radius rod for any sign of damage to the rubber © If damaged, remove the rubber bushing with the tool A3.0211 (see figure) © Insert the new rubber bushing with tool A021, © Reinstall the radius rod onto the car In reverse order of removal © Tighten with 2 torque wrench + the nuts securing radius rods to rear axle to 115-13 Kgm (82-94 Ib) * the nuts securing radius rods to body to WO11.5 Kom (72-05 tbe) WARNING. On completion of suspension assembly check the car for correct aligament To carry out this check disconnect the shock absorbers and stabilizer rod and pul the car under static loud. ‘The dimension © betwoan axle tube and rubber butter must be as specified in the table below. If necessary ada shims in 2 as required and ramove seat 3. lata f200, Gua 900 8, Gian Fi Sita Super (Goi TI Super lula Sprint GT, Gila Sprint 7 Va 55.1 Gua are 2380" | seco seco 34ALFA ROMEO - Via Gattamelata, 45 - 20149 MILANO Diass - Pubbiic. 1222 - 2 - 12/68 (1200)