Gearbox Rebuild - 1967 Alfa Romeo Duetto Spider

The 67 Spider Project needed a total gearbox rebuild after the original gearbox was rough and noisy. In this episode I stripped out all the original gears and replaced everything with better quality parts from a donor box.
Patreon / jethrobronner
Instagram @jethrojamesbronner
#AlfaRomeo #AlfaSpider #ClassicAlfa

[@BrianNavalinsky]

Your videos are so relaxing, they should be required viewing for the criminally insane.

[@Fee.1]

It’s his voice not so much his video ;P

[@hasbeengood]

I said it before, and I'll say it agin: Jethro, you're an artist. Great work. Give yourself the credit you derserve.

[@SkylarkCamperAdventures]

Good on you, taking it on the chin and owning up, lots would have just not said anything 👍🏻

[@JethroBronner]

Can’t hide bad work!

[@SkylarkCamperAdventures]

Jethro Bronner Don’t knock yourself, least you admitted it then was able to sort it. Excellent video. Loved watching it...do I need to get out more?

[@achmadosman9807]

Like watching a watchmaker building a timepiece. Very entertaining

[@cliveengel5744]

Amazing restorations - I remember 1973 - The Oil Crisis, when all Gasoline Stations in SA closed on a Friday at 6:00pm and only opened up at 6:00am on Monday - I drove with my friend in his Alfa Giulietta from College in Pretoria to Cape Town for the long Weekend. We stored Gasoline in the Trunk using empty 25liter paraffin cans, the square ones, as they packed perfectly in the trunk. We made the first leg near to Bloemfontein and filled up and then drove carefully all the way through the Northern Cape, through the Karoo on to Cape Town on our gasoline cans. Wonderful little car and brings back memories of a bygone era. Now, I am relegated to driving a gas guzzling Cayenne Twin Turbo V8 and driving my 1991 Fiat Turbo Uno in Cape Town when I come back to SA. Keep up the good work. Never throw any classic car away!

[@falkirk625]

This should be the gold standard for gearbox restoration videos.

[@JethroBronner]

Thank you!

[@robertfox05]

"i'm new to gearbox building" proceeds to build a gearbox from scratch

[@984francis]

Gearboxes are all about experience. You've done fine.

[@JethroBronner]

984francis and I sure got my dose of experience on this one!

[@aukanmeister]

You have a certain way of the visual artistry that I really enjoy. As well as the technical, of course. Thank you for making the effort😊.

[@JethroBronner]

Thank you very much!

[@gianpaologliori3604]

Amazing work and beautifully filmed! Your workshop is an oasis of calm and reason.

[@thomasthacker4939]

Alfa 105 gearbox - the world's best fidget spinner! ;) - Seriously - excellent video Jethro - probably the most helpful and practical rebuild on the net!!! and a pleasure to watch! - Thanks a mil!

[@JethroBronner]

Thomas Thacker thanks! Yeah I hope I can help out Alfa guys with these videos!

[@davidsauls9542]

I was like your second viewer of this video, but I couldn't comment. I had to digest it. As a physician, all day it is complaint after complaint at the office. Jethro, AGAIN, gets kicked in the belly by this transmission. He is not responsible, but takes ownership of the issue. Here again, he sees it as an ISSUE (rather than a problem where one could be distracted by issuing BLAME to others). While I highly admire your mechanical intelligence, it is your basic raw tenacity that most attracts me. You are an incredibly strong man, in terms of your personality. Very Rare You teach more how to live than about specific automobile issues. Thank you Sir. Keep it coming !

[@JethroBronner]

Thank you! I try to keep the blame limited to my own actions, that way I can actually do something about it.

[@stevewuertz3598]

Nice to see real world (my world) where things need a 2nd run at perfection

[@JethroBronner]

This car seems to need everything done twice. But it's my fault, so I can't complain.

[@stevewuertz3598]

@@JethroBronner I'm a master of the threepeat so you are one better than I've been doing. The thing that is killing me is a lack of extra engines. trans and general parts to move quickly......honestly, its the heat of the Texas summer so I'm not doing much except for some garage remodeling and tool purchasing. Keep on with the motivating work. It's very encourage JB

[@Fee.1]

Jethro Bronner jethro do you have a background video? I’d love to know more about the man behind the proverbial mask. Sometimes I go back and forth wondering “oh so he’s a beginner” to Jfc he’s the fastest learner in history

[@JethroBronner]

Fee I covered quite a bit of it in the Q&A a few months ago, but yeah that’s a good topic for the next Q&A.

[@Fee.1]

Jethro Bronner can you also explain where you attended ASMR training and why you haven’t responded to my love letters? I CAN CHANGE JETHRO. FOR YOU. FOR ME. FOR US. DONT YOU SEE?!?! ;P 😂

[@OccamShavr]

Beautiful photography. A joy to watch your videos.

[@JethroBronner]

Glad you enjoyed it!

[@RonaldFinger]

Quality video and work, as always 👌🏻

[@TheSmokeRecords]

Hey Ron, nice to see you around here!

[@JethroBronner]

Ah dude! Thanks! Now I’m off to check out your bodywork video on Patreon.

[@GreasyFingers]

So cool, the many night shots and the silent blues in the background. 👏🏻

[@JethroBronner]

Glad you liked it!

[@brianpercival1829]

You only learn when making mistakes. 'A Calm Sea Does Not Make A Skilled Sailor'. I enjoy your videos, professional. No stupid childish music, no idiotic dumb face thumbnails. Keep videos like this coming. Thanks Jethro.

[@JethroBronner]

I will do! Yeah I'm trying to make KZbin videos for a higher quality audience, and I can't do that while making them sit through the usual KZbin style.

[@SvenDansk7]

@@JethroBronner Your stuff is absolutely professional quality. IMO possibly the most well-produced car channel on KZbin. Your attention to lighting, the beautiful wooden tables, and calm composure are not going unnoticed. Keep it up; we'll be watching!

[@Robert_Wolf]

"only from failures can true progress be made" - excellent video Jethro. it has been a long time since I did a gearbox it reminded me how satisfying it is to build one.

[@gintonicmunich]

beautiful camera views and explantions - thank you again

[@JethroBronner]

Glad you enjoyed it

[@tonyduncan9852]

Mellifluously rebuilt. Good luck.

[@leighharron]

These videos are a joy to watch

[@woollamiainternationalfilm5285]

The videos themselves are a work of art.

[@JethroBronner]

Thank you!

[@RachaelSA]

I love watching your video's. I thought it was motorbikes next, but this was awesome too, I had no idea they worked similar to a motorbikes gearbox, I had never opened a gearbox from a car, only motorbikes, and had never really given much thought to how they worked. Thank you.

[@JethroBronner]

Rachael Lee The motorcycles are coming up soon! I’m filming the 1st part this weekend.

[@RachaelSA]

@@JethroBronner Good luck :D :D

[@themessenger5868]

Kudos to you Jethro, you are a star for making a video on your mistake...Good on ya for the honestly ! We all make mistakes...!! Your technical know how and skills are something to be admired. I wish I had a quarter of your skill and knowledge. I could watch you work for hours, your videos are "A" class. Cheers

[@JethroBronner]

Haha yeah. I make the mistakes so you guys don’t have to! But thanks man, really appreciate it.

[@arminyack]

Wow, after watching your video, I now realize I need to pull apart a box a rebuilt last year, and replace the 5th gear and layshaft with the taller ratio. My car is a 2L conversion form a 1300Ti, so I've got the shorter one!

[@JethroBronner]

Andrew McGowan hold off on that! 1300Ti models had a standard 5th gear. You can check out which cars had a short or long 5th in that document I mentioned at the end. What diff ratio are you running? Because a 1300Ti will have a 8/41 diff, which is very short. My 1750 powered 1300Ti feels very under-geared on the open road.

[@giuliobaecker5476]

I really like this, I’ve been looking for a Alfa for a while now. Your work and videos are clean. Thanks

[@JethroBronner]

Thanks!

[@antigen4]

jesus - i admire your persistence - if i found the shim was the wrong thickness and i had to refit a new one after all that - that's about where i'd be giving up! it's not like i'd have more than a million in one chance of actually assembling that correctly anyway!

[@JethroBronner]

To be honest I was expecting it to be out, changing main shafts out often caused those kind of issues.

[@tiromancino_tt]

questa scatola del cambio è arte , e tu hai fatto un restauro perfetto

[@JethroBronner]

Grazie!

[@matejhujo5198]

Great Work

[@tuneskramer69]

You make it look easy! Congrats

[@TheStixiy]

For once the KZbin recommandation is perfect, this video is simply perfect

[@JethroBronner]

Thank you!

[@michelesantarelli3450]

I don't know anything in mechanic but watching this video with this quality and craftsmanship it just simple pleasure...good work

[@petersarlai2091]

Rarely do i click this fast. :) Should have gone to bed, but i can make an exception for 1 more Jethro vid .... Thank you!

[@JethroBronner]

Enjoy! Thank you!

[@Plexxarn]

Well done. Not the kind of youtuber that smashes a project together and it becomes "awesome". We all know putting a restored car together means lots of adjustment and rework. It can get the best of you and many projects starts a new hibernation close to the finish line.

[@PhilUKNet]

Your in-depth knowledge of these cars, engineering skills and video production skills never fail to impress me. Great channel, Jethro!

[@johnwh1039]

Undoubtedly a talented guy. If you hadn't said that you weren't an experienced gearbox builder no one would have guessed!

[@1BCamden]

good recovery, very informative

[@Darthvolvo]

Kudos for figuring out what the issue was with the gearbox and correcting it. Your knowledge older Alfas is on point. I always enjoy your cerebral approach to problem solving.

[@JethroBronner]

I think my knowledge is really coming along now.

[@TheEurop24]

Another great lesson from Jethro. I doubt that many mechanics do know so deeply the internals and the fine tuning of the Alfa gear boxes as Jethro does! Thanks for that, and also for the elaborate videography!

[@CowbellCustoms]

Stuff happens, at least you caught it and can fix it

[@ianwynneuk]

The Engineering in your videos Jethro, just never ceases to amaze me. Incredible skill and knowledge - well done👍👍👍

[@JethroBronner]

Thank you very much! I'm not as skilled as I'd like to be! but there's only one way to get there and that's experience, so I'll keep at it.

[@ianwynneuk]

Jethro Bronner is consider what you did as a huge success, particularly with the learning and then identifying the fault. Your knowledge and detail is unbelievable. Huge credit to you

[@motorv8N]

Somehow you manage to create an ambiance of both a technical masterclass and an uber mellow high end spa. I like!

[@classicminidiy]

Mark of a good mechanic is knowing what to do. Mark of a great mechanic is being willing and honest when you make a mistake. Great videos, really enjoy the way you light your subject matter and really enjoyed learning about Alfa gearboxes.

[@JethroBronner]

Thanks man! Yeah working at night is tough because the lighting sucks, but this setup seems to work.

[@HomeBuiltByJeff]

Fantastic work as always and beautifully shot and documented. Gearboxes are definitely something that still scares me ;)

[@JethroBronner]

Home Built By Jeff Until very recently they scared me too!

[@AW_DIY_garage]

Well done. I am rebuilding my own transmission in my Datsun. The removal of your main and counter shaft looks ways easier!

[@glenmcneill1675]

In my distant past we used to the 5th gear and reverse synchro typically to 3 /4th. New synchros were rather expensive and we had lots of time,

[@JethroBronner]

Yeah lots of guys told me they used to move the 5/R synchro to 1/2 as well.

[@paulgallagher1376]

excellent video and excellent work too JB!

[@JethroBronner]

Glad you enjoyed it!

[@marcryvon]

Young man, you do not cease to impress me. I've done a lot of wrenching in my younger years, but I never had the nerve to get into a gear box. Had two of my Datsuns 510 done professionnaly. One turned out great, the second, a 260Z 5 speed swap, errr, not so well. Aaaaargh !

[@alfaromeo6878]

This is brilliant! Thankyou for sharing your experience!

[@petersutcliffe9840]

Beautifully made video

[@JethroBronner]

Thank you!

[@victtorciferri4291]

Thank you so much for sharing this, talking about a mistake this way talks really well about the kind of person you are! And the video is as usual so we'll made and with such attention to detail, keep it that way!

[@JethroBronner]

Thank you so much! I really appreciate it!

[@jcwat]

I usually don't get overwhelmed, but this looks overwhelming lol

[@dg1294]

So calming to watch and such clear explanations as you work. Your videos are an oasis of peace in a troubled world. Thank you from the UK.

[@KarlAdamsAudio]

Thank you for your generosity - creating such excellent videos, sharing your insights, and allowing others to learn from your mistakes too. Also 0:08 - "Please, this is supposed to be a happy occasion..."

[@dalamar6228]

A beautiful piece of work and wonderfully shot too! You have a great balance of explaining what you doing, the reasons behind it and also the engineering and history behind parts and cars too. A lovely blend that works marvellously. Looking forward to the next video.

[@911engineguy]

Hi Jethro, at 7:44 when you install the large retaining clip, it's a good idea to then rotate the opening 90 degrees away from the gap in the dog tooth sleeve.. You might have done it later.. not sure..

[@JethroBronner]

They have a locating tab in them, so they only fit in one position.

[@michaelmoser2130]

Great job man, i can really recommend getting yourself more precise measuring tools if you do this work yourself. I'm a going to be mechanical engineer and apprentice in the industrial mechanics sector. My recommendations would be Mitutoyo or Holex, as they are what my company uses and how relatively affordable to purchase and send in for calibration they are. Greetings and a lot of amazed gazes onto your work from Germany, Black Forrest :)

[@JethroBronner]

Thank you. I'll see if I can find some Mitutoyo tools, might have to save up a bit!

[@michaelmoser2130]

@@JethroBronner it will be worth it, nothing makes you feel shittier than making mistakes because of faulty or inacurate equipment. Been there before :/ It doesnt have to be the most expensive of their lines, but taking care and getting them calibrated every 2-3 years and/or after the fell on hard ground is key. :) Also try not to get suckered in by cheap callipers with digital screens. They only sugest acuracy, as i learned in my apprenticeship and after one or two bigger mistakes. Calipers with digital gages are every bit as acurate/inacurate as their analogue counterparts, they're just easier to read.

[@hjvisagie]

With an exchange rate of $1 = R17 mitutoyo Is quite expensive here.

[@johncrowley5612]

Beware of knock-off Mitutoyo gear. Our Chinese friends are quuick to hijack a good name.

[@jamcdona]

You would laugh at my plastic Harbor Freight micrometer! Hey, it works for measuring (roughly) the ID and OD of hoses and length of bolts...

[@miabamike]

wish all youtube videos were like this

[@troogroove9318]

Another great well explained video, thank you and keep up the excellent work.

[@JethroBronner]

Much appreciated! Will do!

[@mattwilliams8144]

such a beautiful car

[@upfactoryracing4148]

Glad the engine wasn't the problem. That transmission spins like butter now. Like you said the Duetto is that much better now.

[@JethroBronner]

Can't wait to test it out!

[@INNO222]

Great clip!!!

[@KSJone]

Damn, I thought the M45 in my Volvo was complicated haha, great video man!

[@SteezMonsta2]

well done! another A-quality video!

[@JethroBronner]

Thanks again! Glad you liked it!

[@raspucin70]

Sooo...calming :) If I ever need a heart surgery...I'm going to ask for Jethro: "But sir, he is not-" - You've heard me. Just give him a anatomy book and a pair of earbuds :)

[@vitalianolacchini466]

What complexity and what accuracy you need to reaxembling a gear box even in a relatively simple car of the fifties! Nice to see!

[@phillevin6651]

Call me amazed... I just know I’d be totally lost working on a transmission, so many ways to screw it up. Your videos are ASMR, btw. Great work 👍🏼

[@Odesence]

He's back!!

[@JethroBronner]

I'm back!

[@opuscat999]

You are a brave soul to tackle a trans rebuild.

[@petercarlsson6606]

Great video. Thank you. I love the good camera work and that you don't use any irritating music.

[@JethroBronner]

Thank you very much!

[@Velocitist]

Yes, Ya back!!!

[@JethroBronner]

Tom Kao I’m back!

[@moggie100th]

Well done Jethro - thank you for sharing this valuable information!

[@davidraezer5937]

We used to use the non hardening Permatex and one benefit was ease of clean-up when rebuilding. Ultra Grey is good sealant but I would consider using a 3-bond sealer which is soft setting and used for case halves.

[@1222wewe]

i kid you not, but i almost made the same mistake with the 5th gear past week. Fortunately i counted my gears just to be sure. Sadly the original reverse gear was worn thus needing to to open an other gearbox. Also didn't knew about the difference between the yokes and the speed measuring gear, you saved me some time there :)

[@flyingarts6765]

Jethro. Have you thought about cutting off the parts of the bellhousing that were a left over from the column shift cars? I have a 64 TI , since 73, and long ago i cut off those parts and it makes removing and especially installing the gearbox a LOT easier. Don't have to remove the engine.

[@spiderdog762]

Fantastic, informative; really well filmed. I love those old Alfas.

[@fiffe7782]

3:48 My New Desktop Background

[@GTVAlfaMan]

Good job. Hello from Los Angeles.

[@garethneal82]

Jethro. I love this work. But please get a digital micrometer for measuring those shims. A calliper resolution is +\- 0.05mm so measuring 0.1mm steps is only just useful. Callipers are for scribing lines and pulling splinters. As my old supervisor would say.

[@samcoote9653]

This video is gorgeous, love the meticulous work you do man. Makes me dream about getting an alfa every time i see a vid

[@AlbertManiscalco]

Zen and the Art of Alfa Spyder Maintenance 😁

[@camsmeltzer9388]

Hey that's me! Take everything apart twice... Lol. Well done.

[@davidrademan4196]

I empathise deeply, having just reinstalled my Triumph gearbox due to an idiotic, self-induced selector issue. We've got the same heatgun - try placing it on its butt after use unless you're not too precious about it, I heard that their hot internals can eventually melt through the plastic case otherwise. Also, nice to see another SAfrican using KT sockets, and Loctite Grey (praise Midas).

[@JethroBronner]

Praise Midas indeed!

[@HansBrodiAutomotive]

Hey KZbin-Algo give this man more views!

[@modelleg]

Really great work. Thank you, JB.

[@JethroBronner]

Thank you!

[@SkylarkCamperAdventures]

Kudos for attempting that.

[@rubenaerts752]

Great work as always! Wish I could do what you're doing!

[@jamcdona]

Great video, the community needs these! When my gearbox was rebuilt, he only used a new 2nd gear synchro. The rest he said that he 'flipped around'. I don't quite understand what that means, but I've heard as many arguments against that method as for, so I still don't know what to think. My first gear tends to need more time to shift into from neutral than the other when warm. Irritating.

[@JethroBronner]

Only one side of the synchro ring actually woks, so flipping them when they still have a side with 100% friction left is a good option, it would be a waste not to. But you also have to make sure the sleeve and dog teeth aren't also worn. Many people just change the ring, but then the shift still isn't great.

[@johnkahts7698]

Nice one.

[@Aidan.Sheahan]

My second gear synchros thank you for this one 😅

[@JethroBronner]

No problem 👍

[@samcoote9653]

Hey Jethro!! Hope youre doing well man! And good to see you have the heart to admit you made a mistake, honestly, it really didnt look that different of a ratio until you had the close up. I probs wouldve done the same. This video is great already! Cheers mate

[@markufoto]

Would love to see you take apart a desmo Ducati 😊

[@jasongargiulo3984]

Clever, clever guy

[@alfistiadventures9369]

Ah... the set backs that make you stare in to the distance wondering why.

[@JethroBronner]

Alfisti Adventures yeah I’ve been doing that a lot with this car!

[@titanus49]

Great work Jethro. These gearboxes are a work of precise engineering. Many years ago, I had my Giulia Super gearbox overhauled,the mechanic told me that if I wanted to upgrade the gearbox to fifth gear roller bearing,instead of the sleeve. All he did was use roller bearing from a 1750 gearbox,without having to modify anything else. Is it possible to get the red stick on label, that goes on the side of the gearbox, on which oil to use (EP90) ?

[@JethroBronner]

I think you can get them on Ebay?

[@dougsmith1622]

Jethro, where did you aquire your mechanical knowledge? Your videos are really good, thanks.

[@JethroBronner]

10 years of Alfa Romeo ownership will turn you into either a master mechanic or an alcoholic, I chose the former option.

[@SeasideGarage]

you channel makes me want a Alfa Romeo... :)

[@JethroBronner]

Do it! It's totally worth the headache!

[@eddiegerlach7121]

Jethro, where can I get those beautiful engine stands? Mine attaches to the back end of the engine, and can't help but feel it's way more stressful to the block than bolting to each side of the block...thanks!

[@stavrosmoullas9758]

This is Zen

[@usmaank]

13:12 pardon my ignorance, but I'm curious about the reasoning for swapping the shim. From what I can understand shims are sort of like spacers to get gears aligned upto spec? If so, how does a decrease in shim thickness (0.4mm to 0.1mm) result in an increase in the distance from 3rd to 4th gear (from the original 41.7mm to the new 42.1mm). Again, just curious, I have 0 knowledge in this field. Awesome video though!

[@JethroBronner]

OO7 so the middle bearing sets the location of the main shaft. If you have a thicker shim it moves everything away from the bearing, and a thinner shim moves everything towards the bearing.