Jonn investigated the possibility of repairing the bellhousing on our 1963 Fiat 500 where the starter motor bolts on, attempting to do so with the engine still in place. However, due to limited access, he stripped and removed the engine and gearbox. Once separated, the gearbox was washed down in the damaged area and handed to Clinton for repair. Jonn also removed a broken starter bolt from the engine block and drained the gearbox oil to allow it to be stood on end for the repair.
With the engine out, he checked the ancillaries and taped up a battery wire that had been chafing. The starter bolt holes in the block were drilled and fitted with 10mm helicoils. The bolts were checked to ensure they passed correctly through the starter, and the starter body and bellhousing thicknesses were measured: 9mm and 18mm, respectively, making a total of 27mm. It was confirmed that 10x50mm bolts would be suitable, providing 20mm of thread engagement in the block to hold the starter securely.
Clinton completed the repair to the gearbox, grinding down the welds to ensure a flush fit for the starter. Clinton also modified a starter bolt for Jonn, who then fitted and secured the starter. Gearbox oil was topped up before Jonn, with John’s assistance, refitted the engine and gearbox, securing all mounts and correctly routing cables and wiring.
The installation of the engine and gearbox was completed with all connections made and secured. Cables to the carburettor were routed and connected, and the choke and throttle operation were tested. The battery was reconnected, and the car was run up to check all gears, with the clutch adjusted as needed. A test drive around the yard confirmed basic operation.
Several faults were identified during the process: the dynamo light remained on, indicating the car was not charging; the bonnet cable was broken; the engine idle was poor and it occasionally stalled; and the nearside rear brake was binding. It was advised to leave the faults as they were for the time being.
