Boxer/Testarossa high performance crown and pinion | FerrariChat
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Boxer/Testarossa high performance crown and pinion

Discussion in 'Boxers/TR/M' started by Newman, Oct 18, 2011.

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  1. Newman

    Newman F1 World Champ
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    #1 Newman, Oct 18, 2011
    Last edited by a moderator: Sep 7, 2017
    I had a request for a custom rear axle ratio for a Boxer from a very well known ferrari dealer in the US. They also wanted a carrier so I tooled up for another batch of carriers and had a gear set made, ratio is 3.69:1 vs the stock 3.21:1 that all 512 boxers and Testarossas are equipped with. I planned to run the same ratio in my boxer so I already had the maximum numerical ratio figured out that will fit the gearbox. Minor machining is required (or grinding depending on your personal preference) to fit the new ratio but its minor. I also came up with a support reinforcement that will aid in reducing damage or failure of the left side support cover whether you run a stock ratio and want added insurance or run the higher numerical ratio for a substantial increase in acceleration in all gears.

    The support I came up with is what I call a girdle which is a take on what Ive run in muscle cars to keep the carrier caps in place under load. Because of the hypoid gear design, under load it's effectively trying to push the carrier and crown gear away from the pinion gear. This tendancy effects the gear contact pattern not to mention it makes the left side cover move in the case as indicated by witness or wear marks. Its obvious it moves back and forth. With the girdle installed, it provides a solid surface for the carrier cover to butt up against. Through the use of a second steel block that fits into the ridgid rear engine mount cover thats webbed, it employs a jack screw that is adjusted through the oil fill hole once the cover is installed (No modification required - plug and play). The jack screw preloads the carrier support lightly so its not pushed forward but instead has something to brace it from moving. This will prevent any rearward movement of the left carrier side cover and stop flex of that cover.
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  2. Cruiser

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    #2 Cruiser, Oct 19, 2011
    Hi Newman, what grade steel has been used and what are the costs involved? Which part should be machined?

    Another amazing product which I believe is of a very high standard and will prevent a lot of tears.

    Thanks Newman. People like you make this forum what it is.......... AMAZING.
     
  3. samsaprunoff

    samsaprunoff F1 Rookie
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    #3 samsaprunoff, Oct 19, 2011
    Good day Paul,

    What can I say, but well done!

    Cheers,

    Sam
     
  4. blu328gts

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    #4 blu328gts, Oct 19, 2011
    WOW! Outstanding work, Paul!!!
     
  5. CornersWell

    CornersWell F1 Rookie

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    #5 CornersWell, Oct 19, 2011
    I still want 4 sets and the carriers in Ti!

    CW
     
  6. wlanast

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    #6 wlanast, Oct 19, 2011
    I think I know the answer to this, but have to ask a stupid question anyway.

    Does the reinforcement you made to support the left side cover increase friction or further increase power loss through the drive train?

    I assume not since it is either pushing against the cover or the girdle you made, but perhaps the positioning of the reinforcement changes that.

    Nice work!
    W
     
  7. Newman

    Newman F1 World Champ
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    #7 Newman, Oct 19, 2011
    When would you like to place the order? :)
     
  8. CornersWell

    CornersWell F1 Rookie

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    #8 CornersWell, Oct 20, 2011
    When I hit the lottery, apparently!

    CW
     
  9. marioz

    marioz Formula 3

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    #9 marioz, Oct 20, 2011
    Nice work Paul.

    If you don't stop now you will be building a complete car in the future.
     
  10. Gleggy

    Gleggy Formula 3

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    #10 Gleggy, Oct 20, 2011
    Wait for it, Newman won't let this slide.
     
  11. Newman

    Newman F1 World Champ
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    #11 Newman, Oct 21, 2011
    8620 carburized and hardened. The shop has been making gears for over 25 years, showed me around the shop and got to see some pretty interesting machines. He gave me a lesson on gear designs etc etc....Long story short you have to take 2-3mm out of a web in the box because as you increase the ratio numerically, the crown gear increases in thickness.

    No it doesnt effect the setup of the gears or it would cause damage not just a friction increase, it keeps the gear setup in place under load. This gearbox is full of shortcomings and could use a redesign in my opinion but dont worry thats not next on my list. :)
     
  12. open roads

    open roads F1 Rookie

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    #12 open roads, Oct 21, 2011
    You da man !

    I think it's great work. I'd like to get a set as I'm going into a race project.
     
  13. Newman

    Newman F1 World Champ
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    #13 Newman, Oct 21, 2011
    3.69:1 is the highest I can go numerically but you may want something different. I wonder what the LM's are running for ratios?
     
  14. CornersWell

    CornersWell F1 Rookie

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    #14 CornersWell, Oct 21, 2011
    I'll check for you.

    CW
     
  15. Cruiser

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    #15 Cruiser, Oct 24, 2011
    Hi Newman, what are the costs involved when buying just the gear set for now.
     
  16. Newman

    Newman F1 World Champ
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    #16 Newman, Oct 24, 2011
    $6k Canadian funds any ratio. If it goes to the US it's duty free because of the free trade agreement.
     
  17. jrbaldwin

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    #17 jrbaldwin, Nov 27, 2011
    I own a early 1988 Testarossa and will be doing a engine out service in January and would like to install your upgraded carrier & gear set. What would be the cost of complete upgrade kit in the stock 3.21:1 gear ratio.

    Jim
     
  18. ~Joshua

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    #18 ~Joshua, Nov 28, 2011
    Last edited: Nov 28, 2011
    Silly question... where is the output for the speedometer?

    I mean, does changing the ratio require an additional change to make the gauges correct?

    On other cars I know the speed is taken from the transmission, so it wouldn't affect anything with a differential ratio change.

    Some other cars would have the wrong speed with a ratio change... curious to know about the TR.

    Thanks for your time!
     
  19. Spasso

    Spasso F1 World Champ

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    #19 Spasso, Dec 12, 2011
    The output for the speedometer is at the forward end of the transmission on the driver's side (US Spec), at the front of the engine.. IIRC it's a pulse generator to which two wires are attached.
     
  20. uzz32soarer

    uzz32soarer F1 Rookie

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    #20 uzz32soarer, Dec 16, 2011
    I'm with James, Paul, can you confirm that you can maufacture a replacement crown wheel and pinion for the Testarossa in the stock ratio.

    Does this still require a new set of Ferrari bolts to mate it to the diff centre. Apparently the new 512TR/M bolts are different to the early ones.

    I also don't understand the Canadian Taxes issue. What GST / VAT is payable if the product does not get sent to the USA but to another country?
     
  21. Newman

    Newman F1 World Champ
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    #21 Newman, Dec 16, 2011
    If you have the lock tabs for the ring gear bolts you would upgrade to the self locking bolts. You can get a stock ratio of 3.21:1 no problem. If someone opted for a different ratio that's no problem either but the speedo would need to be calibrated or it will read high.
     
  22. jim fuchs

    jim fuchs Rookie

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    #22 jim fuchs, Dec 19, 2011
    Hi Paul,
    The ring/pinion ratio for the "T.3.LM" later series 512 BBLM transaxle is 9/31 (3.444 ratio).
     
  23. Newman

    Newman F1 World Champ
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    #23 Newman, Dec 19, 2011
    Thanks jim!
     
  24. shopcarpro

    shopcarpro Rookie

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    #24 shopcarpro, Jul 8, 2021
    Hi, I am in need of fixing my blown differential ( 88 TR ), My Pinion is OK. The parts of the center of Crown wheel is shot, so are the planetary assy.
    Let me know, if you can fix this for me pls. [email protected] - 213 260 4274 --- Thanx in advance, Henry.
     
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  25. boxerman

    boxerman F1 World Champ
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    #25 boxerman, Jul 14, 2021
    Paul you continue to blow me away.
    You're developing the boxer as ferrari should have, the true potential of these cars is shining through.
    Im imagining a BBI high comp pistons with your reprofiled cams(which worked fine with the FI) so the motor can continue to make power up high and a shorter gear ratio, wowza. A stock BBI is more or less past its power peak and falling off y after about 6200rpm, if one can make soild power up to 7k rpm and with the changed ratios the net effect is going to be huge.
    Did the koning have different gear ratios?

    Any calculation as to what revs at certain speeds/geas 3-5 stock vs the new ratio.
     
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