1967 ALFA ROMEO SPIDER

Typical onset: 80,000-120,000 mi

Symptoms: excessive oil consumption (quart per 500 miles), blue smoke on deceleration, low compression across multiple cylinders, knocking or rattling from bottom end, oil pressure drops below 20 psi at idle when warm

Fix: Full teardown with machine work: bore cylinders, replace pistons/rings, grind crank, new main and rod bearings, valve job with guides and seats, new timing chain and tensioner. Expect 40-60 hours labor depending on parts availability and machine shop turnaround. Most shops pull the engine entirely for access.

Estimated cost: $6,500-12,000

Typical onset: 70,000-100,000 mi

Symptoms: grinding into second gear when cold, difficult engagement of third gear under load, popping out of second during deceleration, sloppy shifter with excessive play

Fix: Manual transmission rebuild with synchro replacement for 2nd and 3rd gears, new shift forks if worn. Transmission mount replacement almost always needed simultaneously as rubber degrades and allows excessive movement. Rebuild typically 18-25 hours including removal/installation.

Estimated cost: $2,800-4,500

Symptoms: rough idle and stumbling, hesitation on acceleration, fuel leaking from carburetor bases, hard starting when warm, black smoke and fuel smell from exhaust

Fix: Webers need rebuild kits every 10-15 years whether driven or not: gaskets harden, accelerator pump diaphragms crack, needles wear. Ethanol fuel destroys old rubber lines and cork float bowls. Full carb rebuild with synchronization, new fuel lines, filter, and pump runs 8-12 hours. Proper tuning requires experience with these specific carbs.

Estimated cost: $1,200-2,200

Symptoms: visible rust perforation along rocker panels, soft or flexing floor pans when pressed, cracking paint around rear shock mounts, doors sagging or misaligned, water intrusion into cabin

Fix: These unibody Spiders rust from the inside out, especially in rockers (inner and outer), floor pans under seats, and rear shock towers where water collects. Proper repair requires cutting out rot and welding in new metal—not Bondo over screens. Quality restoration bodywork easily exceeds 60-80 hours. This is a deal-breaker issue on most examples.

Estimated cost: $8,000-18,000

Typical onset: 90,000-140,000 mi

Symptoms: severe knocking from bottom end, metallic rattling at idle that worsens with RPM, sudden loss of oil pressure, metal shavings in oil filter, vibration through entire drivetrain

Fix: Usually caused by oil starvation, old age, or running the engine low on oil. Requires complete disassembly, crankshaft removal and grinding (if salvageable), new main bearings, and typically new rod bearings while you're in there. Often discovered during rebuild. Engine-out job: 35-50 hours total including machine work coordination.

Estimated cost: $5,000-9,000

Typical onset: 80,000-110,000 mi

Symptoms: gear oil leak from pinion nose, whining noise that increases with speed, clunking when shifting from drive to coast, vibration at highway speeds

Fix: Pinion seal replacement is straightforward but while you're there, inspect ring and pinion for wear patterns. These diffs run hot and gear oil was often neglected. Full differential overhaul with bearings and seals runs 12-16 hours. Limited-slip models add complexity and cost.

Estimated cost: $1,800-3,200