Stepper Gears: Dash Disassembly/Assembly
Tools and Parts

[Steppers Access (Index)] [Access Introduction]
[Steps 1-5] [Steps 6-11] [Steps 12-15] [Steps 16-20] [Steps 21-25] [Steps 26-30]
[Steps 31-35] [Steps 36-40] [Steps 41+]

About the Dash Disassembly/Assembly Pages

The notes in the "Steps" pages follow the directions given in the Alfa 164 technical service bulletin (TSB) 80.93.02 from ARDONA (Alfa Romeo Distributors of North America). ARDONA also produced a video (NTSC system only, part #608-97496) of this procedure which is still available from suppliers in the USA and also on a CarDisk CD-ROM (Windows only).

As well, some variations in specifications occurred over the life of the 164, and for different markets worldwide. The ARDONA notes referred to North American cars (LHD) for the years 1991-93 (see also the following diagrams). However the photographs in the disassembly pages (Steps 1 through 41+) show the dash procedure on an early model (built late 1988) RHD model (Australian delivery).

Tools Required
Close tolerance offset screwdriver (preferably ratchet - it makes the job faster). "Close tolerance" means a very small distance between the tip of the bit and other face of the screwdriver arm - there is very little room for you to operate in between the top of the dash and the underside of the windshield (windscreen).

Our close clearance offset screwdriver was made using a long 6mm box end wrench and a #2 phillips power drive bit for the smaller screws and a #3 for the larger screw/bolts. Some experimentation may be required.

In the USA, ARDONA suggests Sears/Craftsman wrench - part number 42952 and a #2 phillips bit from a Black & Decker 5 pack - part number 71-468. Make the modified Sears ratcheting offset screwdriver using Sears part number 41121.

Long-reach phillips #2 screwdriver (flexible along its length is an advantage). This needs to be perhaps 16 inches (40 cm) long.

Plastic strips to remove end vent covers. An invention of ours to facilitate easy removal and prevent damage. The plastic strip has be thick and strong enough to be tear-proof but flexible enough to bend a little into place. We cut up a video tape box, about 2mm thick.

Make the plastic strip about 6 inches long and 1inch wide. One inch from one end, cut a small square or semi-circle of plastic from one side half an inch across to the other side.

Picks or small flat screwdrivers or similar to remove trim pieces.

Parts Required
Replacement stepper gears - of course we recommend our own AlfaPro replacement gears (full set required per car, for two stepper gearboxes). These precision-made steel-and-bronze gear-sets are installed in 164's in many countries around the world. Their installation compatibility, reliability and durability is so far 100% successful. Alternatively, you may choose to replace the stepper gearboxes with new, original Bosch (Alfa) parts. While normally we recommend original parts over other types, in this application we feel compelled to warn that the life expectancy of such parts, even "original" parts, will be no better than the ones you have removed. Also, we know of no other replacement gears which match the durability and quality-control of AlfaPro. They are individually made and thoroughly checked before being dispatched. (So much fuss about some little gears!... but when you've read through this web site you'll see why it's important to get this job right the first time).

Speed clip or shaft clip- to fit on the air temperature stepper arm shaft (5mm). You should do the sensible thing and cut the old speed clip off rather than risking damage to the stepper arm by trying to get it off intact.
- PROVIDED WITH EACH ALFAPRO STEPPER GEAR SET OR HALF-SET.

Reinforcing ring - to fit the air distribution drum to prevent breakage (or to repair breakage) of the plastic stem of the drum which fits onto the air distribution stepper motor gearbox.
- OPTIONAL TO PURCHASE WITH EACH ALFAPRO STEPPER GEAR SET OR HALF-SET

ARDONA Technical Service Bulletin 80.94.01 has a little more information and a diagram that's marginally useful.

LEFT TO RIGHT: STEPPER MOTORS (LHD: two attached to one electrical connector. RHD: separate connectors).
STEPPERS MOUNTING BRACKET (LHD shown. RHD has two different brackets). BELOW: TEMP SENSOR FAN MOTOR
STEPPER GEARBOXES (TOP: AIR DISTRIBUTION, BOTTOM: TEMPERATURE OR AIR MIXING)
LONG-NOSE PLIERS, OFFSET SCREWDRIVER, SCREWDRIVERS

Photo © Lennart Krook.