| There are two likely culprits. Clutch Actuation
If the transmission is reluctant to go into any gear, the most commonly found problem is in the hydraulic clutch actuating mechanism. This consists of a master cylinder (and reservoir), mounted to the firewall and attached to your brake pedal, and a slave cylinder, attached to the clutch lever. These two cylinders are connected via metal and rubber tubing. Since the slave cylinder operates out in the elements, subjected to road dirt, water and salt, it's the more likely problem. The good news is that slave cylinders are relatively inexpensive. We recommend replacing the rubber portion of the tubing, if it's more than a few years old, since it can become degraded internally and cause problems--and it's also inexpensive. You should also consider replacing or rebuilding the clutch master cylinder; it's a bit easier to do now, since you have to bleed the system anyway. The Transmission
If your Alfa transmission goes into gear relatively easily when you put it into gear in your driveway, but makes a crunching noise when you shift (especially into 2nd gear), the problem is likely to be worn synchromesh rings. There’s nothing special about second gear, except that it tends to get the biggest workout--especially around town. Unfortunately, synchromesh is quite a bit more expensive to fix than a clutch slave cylinder. To make the repair, the transmission should be rebuilt with new synchros (plus seals and any other worn bearings and gears). As an alternative, IAP has rebuilt Alfa transmissions, so you can swap yours out without waiting for a rebuild.
The good news is that you can delay the synchro repair if you must. First, make sure the gearbox has the correct oil (and is filled to the correct level). Then, whenever you drive, do the following: each time you shift, pause briefly in neutral before engaging the next gear. When you downshift, rev the engine a bit, to the point where it will already be at the correct rpm for the next gear. By shifting slowly and deliberately, and learning to avoid the crunching sound, you may be able to keep enjoying your Alfa through the season. - Mark Lee
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