Clling on the brotherhood - a 348 Gerbox problem... | Page 2 | FerrariChat

Clling on the brotherhood - a 348 Gerbox problem...

Discussion in '348/355' started by Marco Bussadori, Jul 31, 2008.

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  1. Marco Bussadori

    Marco Bussadori Formula Junior

    Aug 6, 2007
    430
    London
    Full Name:
    Marco Bussadori
    Wow, I can see how the gear fit and am amazed the edges of the shoulder on the gear is still intact on the side that must just have protruded past the splines on the shaft. It almost suggest the gear was not pressed all the way in over the splines, reinforcing FBB's suggestion they used the ring nuts to press the whole assembly instead of first pressing the gears down. I'm assuming that is your first gear right, it certainly looks like the layshaft.

    By the compression, I can see the two metals are of the same density, meaning there is just not enough surface to absorb the energy of the car's inertia when the momentum changes, hence why they needed more splines. Providing these have bases thick enough to withstand the shearing forces, they would need at least 15% more splines to overcome the stresses.

    Great, so another thing to look for... I'm wondering if this is actually worth it...
     
  2. Ricambi America

    Ricambi America F1 World Champ
    Sponsor Owner

    #27 Ricambi America, Aug 5, 2008
    Last edited by a moderator: Sep 7, 2017
    Yes... 15% more splines would look like the new style shaft!


    (yes, I'll get a better picture eventually...)
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  3. SonomaRik

    SonomaRik F1 Veteran

    Something tells me these errant gearboxes, aka the threaded nut problem, is ONLY a certain range of SNs. Many NEVER experience this issue.

    THere seems to be a factory change in procedure that when pressing that gear on, they used the nut for the last seating, rather than a press machine: wrong.

    I'll almost bet, if the failed tranny, persons came fwd, with their build-dates/SNs that we'd trace the issue to just that.

    I've had mine inspected and it's perfect. '90 Mondial T NOW [I've trippled the mileage since I've owned it] to 33k.

    ok, now having said that: knock on wood
     
  4. Ricambi America

    Ricambi America F1 World Champ
    Sponsor Owner

    Mine blew at 47k miles. s/n 86426
     
  5. SonomaRik

    SonomaRik F1 Veteran

    Hmm: Mine 1990, 33k miles s/n 86247
     
  6. ernie

    ernie Two Time F1 World Champ
    Lifetime Rossa Owner

    Nov 19, 2001
    22,620
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    #31 ernie, Aug 5, 2008
    Last edited: Aug 5, 2008
    Thanks for letting us know what came about with the gear whine.

    Your mechanic is totally correct in telling you that you are looking at some big quid to change that rear out put shaft. It is totally in the back of the gear box and you must remove EVERYTHING to get it out. There is no other way about it.

    However........

    Maybe the Stooges are game for another gearbox tear down session? What do ya think fellers? A Stooge trip to Jolly 'Ol England? Though you are gonna have to get ahold of the pinion gear first.
     
  7. Ricambi America

    Ricambi America F1 World Champ
    Sponsor Owner

    #32 Ricambi America, Aug 5, 2008
    Last edited by a moderator: Sep 7, 2017
    Mine came out without dismantling the entire gearbox.... but it cannot be swapped without a dismantle. Mine was simply 'fixed' :) (until other gremlins got the box)
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  8. ernie

    ernie Two Time F1 World Champ
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    Nov 19, 2001
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    Okay wait a minute here. Are we talking about the same "pinion" gear? I'm talking about the one that runs the ring gear on the main shaft.
     
  9. fatbillybob

    fatbillybob Two Time F1 World Champ
    Consultant Owner

    Aug 10, 2002
    29,256
    socal
    NO they be all messed up with terms. Clutch shaft is what Ricambi has posted. IMO that is easy to fix too. I actually replaced my 348 clutchshaft with the same 348 thick spline shaft. The spline is not the issue but again the staking of the ring nut is because there is force on it because the gear is not straightcut. If this nut is staked properly there is no play to eat the shaft. This splines increase friction and reduce the need for tight ringnut. But why would you leave it loose anyway. To me I would buy whichever shaft is cheaper. I have pictures of my destroyed shaft just like Ricambi's with my stake ring UNSTAKED as it came from the Ferrari factory. Obviously too much vino at lunchtime... When I sent my pictures to Ferrari they could care less. The thin spline shaft adds more friction and removes the needed torque to the ringnut. So they redesigned the part to make up for sloppy install....typical Ferrari. This is why I asked Marco if a stethescope was used because you can hear the difference between a pinion gear AKA Bevel gear (that huge ice cream cone looking thing ) and play in the clutch transfer gears. Marco, DO NOT underestimate that small noise if it is in the transfer gears. Huge force goes through there and that can eat itself and crack a gearbox case then you can't even rebuild it. Once the gear box is together you can prusian blue the Bevel gear to see how it mates. Bad mating could be your noise. Good mating would point to the clutch shaft gears. This is why I am big on diagnosis before repair. You don't do heart surgery then suddenly decide to replace a kidney too. This shaft is easy to remove at this time to inspect the gear integrity and tighten that ringnut as well. These problems are easily solved if people think first and act second and it will cost you alot less too.
     
  10. Marco Bussadori

    Marco Bussadori Formula Junior

    Aug 6, 2007
    430
    London
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    Marco Bussadori
    #35 Marco Bussadori, Aug 6, 2008
    Last edited by a moderator: Sep 7, 2017
    Status
    1) I caught the bearing in time - it was the one on the oil pump shaft - lay shaft. The layshaft one was perfect (but got changed too). The outer bearing ring race looked OK, most of the balls were fine. The ball retaining guide ring was showing of sided wear, eg. rubbing, and the inner bearing race half towards the outer side of the g-box all galled. See the pictures below and the same as (http://ferrarichat.com/forum/showthread.php?t=157349&page=4). Interestingly, these bearings did not have the brass guides, but the same metal retaining guide ring as the new ones I got AND they showed evidence of seizing as there were rotational marks on the outer surface and on the case frame.
    2) All the ring-nuts were "dimpled". I use that term instead of "staked" for a reason. We slotted a screw driver in the staking slot, pried up 10 degrees, and I unscrewed the lay shaft ring nut by HAND!!! The Main shaft one took a LIGHT wrench turn. The ones on the other side were a bit better, but hey they are not designed for thrust. There was ABSOLUTELY NO Loctite on anything in there, I mean NONE WHATSOEVER!
    3) There was only slight metallic "mud" on the sump plug and VERY fine metallic bits that looked like bearing race fragments in the plastic filter basket.
    4) The ring nut on the input shaft (the one coming from the clutch, and connected to the bevel gear one) was also dimpled, but loose. This made the pinion gear slip and shows the same damage as Daniel's above (though about 1/3 as bad) - see pictures. This is apparently a well known problem. The ringnut was so shallow in its dimpling that it could just be turned within the dimple by hand, and forced off with a very light wrench turn. - Again no Loctite.
    5) The aluminum "plug" at the end of the lay shaft (opposite side of the oil pump), which is meant to block the end of the hollow shaft so the pressurized gearbox oil goes THROUGH the system was unscrewed and "rolling about" in the casing. Thankfully it was of light aluminum, so it got beat up without damaging the shaft. That has been replaced with a new one, and Loctited!
    6) The BAD NEWS is the shaft gear driving the crown wheel, it is pitted on about 5-6 of its teeth (all in a row and not at random) It does not look like these were affected by the bearing , but who knows, if the shaft shifted a bit, then that could... Mike Lester at Rardley Motors (a true gentleman mechanic and Ferrari owner/driver) the majority of boxes seen in early cars have this prob apparently. As the cost (despite not easily available) of these gears is in excess of a replacement used box, I'll go with leaving it as it. The mating faces on the crown wheel side are perfect.
    5) Found the small bearing on the flywheel to be rough, the throwout bearing to be rough and the clutch to be worn to 3mm on all grooves, but less on the outer face of the one disk. I will replace it at the next cam belt service in 6 months or as soon as it slips, whichever comes first - I just can't afford it now!!!
    6) Prussian on the bevel gears showed good mating - thanks FBB.

    Solution:
    In the next few days we will:
    1) Replace the bearings, tighten ALL the 4 ring nuts, after drowning the threads in Loctite 271. These will then be STAKED so to break the lip into the recess in the direction locking it.
    2) Loctite the pinion gear from the clutch shaft on the splined shaft. Tighten the hell out of the ring nut and locktite it as well as STAKING it.
    3) Reassemble it all and drive it like I stole it, until the next thing goes wrong.
    4) Flywheel will be re-greased

    COST:
    2 shaft end bearings, 1 small flywheel bearing, 1 throwout bearing, a few other tid-bits and 25 hours of work = GBP 3600 (USD7200) EF-ME!!!

    Comment (a bit of self gratuity):
    He said, I caught the sound in time. Also the box shows that a very precise use of the gears has been done since it started as there is no evidence of the bearing having had any effect on the box as may have been expected with the damage on the races.

    Failure modes:
    I the use of the ring-nut was to press the gears home (both the clutch shaft gear and lay shaft gear are like this and both are the main culprits in the main reasons), coupled with the lack of proper staking and not using Loctite, suggests that the tightened assembly will loosen on the splines with use, then the rotational forces will start loosening the ring-nut.
    a) On the clutch shaft, this causes the increasing compression crushing of the splines, which in turn causes increase movement and increases the loosening of the ring-but - thereby kicking off a vicious cycle.
    b) on the lay shaft, the loosening will allow movement of the shaft outwards with acceleration (as it is the outer race that fails and the thrust line of the gear under force is to push the shaft outwards), then back inwards with deceleration (I saw friction marks between the outer casing and the plug at the end of the lay-shaft) - I suspect this is the cause of the lay shaft gear wear visible in the pictures. As the ring-nut works itself back, the additional play allows for off axis twisting of the bearing race which sets off the failure process of the bearing as the balls are no longer aligned with the races and the retainer ring. Clearly as the gears start moving past the alignment point, eventually they will enter a conflicting configuration and we have the catastrophic failures with forces that can threaten the integrity of the case.

    In reality I think FBB got it right, blaming the ring-nut assembly and tightening process.

    Pictures enclosed!!!
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  11. ernie

    ernie Two Time F1 World Champ
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    Nov 19, 2001
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    #36 ernie, Aug 6, 2008
    Last edited: Aug 6, 2008
    Thanks for the update Marco, and I'm glad you listened and stopped driving the car.

    Just so you don't feel bad, you got off relatively easy. The main ring and pinion (bevel) gear in my transmission when out and it was retarded money to buy a new one and, NO ONE in the United States had that part. I was finally able to get one through Ricambi, and Daniel was a BIG TIME help in sourcing it through his guy, who knows a guy, who knows a guys cousin. :D If you would have had that gear go bad, and had to pay to fix that one (only sold in a set) you can just multiply your repair price by x3, no joke.

    Glad you're getting it fixed.
     
  12. FandLcars

    FandLcars F1 Rookie

    Aug 6, 2006
    3,057
    Tempe, Az
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    Rick Schumm
    This is really valuable reference material for 348 owners. Thanks Marco! :) Sorry you had problems, but glad you caught it before things became even worse.
     
  13. fatbillybob

    fatbillybob Two Time F1 World Champ
    Consultant Owner

    Aug 10, 2002
    29,256
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    Loctite makes a product to help the fitment of worn parts of gear 8 with clutchshaft 9. I am glad you have read my lockring assembly method. So far I have not had one box come back and my box was extensively raced. Please make sure you feeler guage the synchros since your box is partly apart. If gear 8 has any play on shaft 9 it will blow up in a short time and replacing the shaft and the gear would require you chage it's pair on the bevel gear = big bucks!!!
     
  14. No Doubt

    No Doubt Seven Time F1 World Champ

    May 21, 2005
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    Great followup, Marco!
     
  15. Blackspider

    Blackspider Karting

    Mar 2, 2004
    162
    the type of gearbox issue that is being shown up is this limited to earlier models of the 348, like tb/ts? or later models like GTC/Spider? My 348 will going in for its 30k service soon and the gearbox will be looked at so should have something to report with regard to internal condition.
     
  16. ernie

    ernie Two Time F1 World Champ
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    I'm not sure if it is just a particular year or not? My car is a '90 and had the problem. I think it has more to do with whoever was putting together the gearbox at the factory more than the build date. Not every car has the problem, but it is becoming more and more common, and almost always it's the same problem with the ring nuts not being tightened and/or staked properly.
     
  17. Blackspider

    Blackspider Karting

    Mar 2, 2004
    162
    interesting, in the words of that Candian comedy programme from years ago. As I say mine is in for a 30k soonish and there is a very slight gear whine which will go to the gearbox 'expert' for a looksee, apart from that the box is a beaute all the gears slip in easily, including 2nd on a cold day, will post the results when known.
     
  18. ernie

    ernie Two Time F1 World Champ
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    Well if yours is whining then FOR SURE get those side covers off and have a look at the ring nuts. May as well check the clutch shaft ring nut while you're at it. The worse thing you can do is drive the car and think the whining will go away.

    But first things first.

    Check to make sure that you are not low on gear box oil, because low oil will also result in gear whine.
     
  19. saw1998

    saw1998 F1 Veteran

    Jun 8, 2008
    8,237
    San Antonio, Texas
    Full Name:
    Scott
    Gentlemen:

    I just finished reading this post. Although I have an F355, it was highly informative nonetheless. I am just posting to say: (i) congradulatoins Marco on your attention to detail and mechanical knowledge/ability - you really averted a potential tragedy (I'm glad you are still a Ferrari owner/fan!) and (ii) I am absolutely amazed at the level of mechanical sophistication and diagnostic ability of some of you FChat members (Marco, Ernie, FBB, No Doubt, etc...)!!! Considering that you are not full-time/factory-trained Ferrari mechanics, you guys are really amazing!! Thank you for sharing you knowledge with us lesser mortals.
     
  20. ernie

    ernie Two Time F1 World Champ
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    Thanks, and.......

    That's RIGHT!!! We are Stooges. I'm just an average guy that turns his own wrenches. Nothing special about this stuff, it's still a car. Lefty loosey/righty tighty ;) You just have to get over the fear of the name, that's all.
     
  21. saw1998

    saw1998 F1 Veteran

    Jun 8, 2008
    8,237
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    Scott
    +1!! I bought the shop/parts manuals for my 308s and 328 - and dug right in! You just have to do your research, take your time, do things right, and be proactive (that than reactive) with these cars. Really no different than any other... except mistakes can be very, very costly!
     
  22. troy_wood

    troy_wood Formula 3

    Apr 28, 2007
    1,457
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    Troy Wood
    Well said - It is because of f-chat and people on this board who do the heavy lifting that make ownership possible for me. I feel fortunate and am looking forward to a time when I can start giving back...
     
  23. fatbillybob

    fatbillybob Two Time F1 World Champ
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    Aug 10, 2002
    29,256
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    Nova Scotia??? How about just telling us where the big salmon are?
     
  24. troy_wood

    troy_wood Formula 3

    Apr 28, 2007
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    haha - yes fbb, just about as far east as one can get. To rise an atlantic salmon is second to none - much nastier attitudes than the pacifics. Biggest problem with this neck of the woods is that there is no f-service (of any kind). Ferrari of Quebec is the closest. That being said I just finished installing my new lift.
     
  25. dra

    dra Rookie

    Mar 30, 2008
    9
    Great thread, thanks for all the info and particularly the pictures!!
    Yes having looked into it, my 348ts 1991, 55k miles---- clutch shaft ring nut dimpled but loose, gear rotational movement on the shaft!

    What would you recommend as a retaining/fill compound to take up the play?
    Cheers
    Pete
     

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