Help. Testarossa stuck in gear

have a look here: https://www.ricambiamerica.com/car-diagrams/ferrari/v12/testarossa-group/testarossa-1987/gear-box-controls.html

may be no. 34 is broken, srew 27 in part no. 36 is loose or missing front or rear, 28 is loose, worst case: 14 is loose, but no need to get the engine out, only a little work with engine inside the car.

I wonder that you get the shifter ( 18 ) in neutral and in reverse, not in other positions?

you need 2 people, 1 inside the car and the other under the car where the back no 27 and 36 are and when the inside guy will move the shifter the other will see what happens. when there is no play in the sytem then it is a problem of the no. 14

 

Yes access is a PITA on a testarossa but you do not need to take the engine out to solve this problem, you will need to remove the front motor mount as there is a blind 13mm nut inside the spacer that attaches to the side cover. Once the side cover is off you will find out what the problem is. I finally got around to setting up my shift shaft this past winter, after I did the major on my car the shifting was not what I expected, some of the more experience people on this forum can set this up by feel but I decided to take the side cover off to look at the setup. It was a bit of a pain to do this, I found the easiest way to ensure things were where they needed to be was to follow the WSM and insert a 8mm to 6mm tapered rod through the case into the blind hole in the shift shaft while second gear was selected, you can then tighten the turnbuckles on the shift shaft. Good luck and please post an update with what you find.

 

Possibly you can get the shifting fork back in position without removing cover. I had my shifting mechanism all screwed up once. Patience under the car with trying different positions got it back. If you remove the trans cover there is a set screw you remove and insert a stepped pin to re set up the forks. The dimensions of set up pin is in manual. Get some one with a lathe to make you one. If you are very stuck getting a pin, PM me with dimensions, I will machine you one. Please use me as last resort

 

Yes no fun to remove the header even without rusty nuts you need to be a contortionist with the engine in position. I took the opportunity while my engine was out to replace the copper flange nuts on the headers, can be sourced from numerous places such as bel-metric. If you do need a pin a simple punch will work or let me know I will send you mine.

 

this all looks pretty good. the 3 forks controlling ( 15, 16 and 17 ) are all right lined up when this should be neutral.
so may be the fork for the 2nd and 3rd gear ( center rod, fork left, in the parts catalog no. 4 - 107374 ) is not really tied?
is the sleeve for synchronizer ( 24, 106038 or 131804 ) exact between the 2 synchromeshrings ( 25, 106040 ) so the loose gears can turn free? could you please make a closer photo of the sleeve and the synchromeshrings from the 2nd and 3rd gear? on the 1st photo I see only the 3rd gear but also I see that the sleeve is not in the middle as for neutral, it seems to be connected to the 2nd gear because to much space to the synchromeshring form the 3rd gear. there is to much shadow/darkness to see the 2nd gear. may be the fork ( 4 ) is not tied or the fork controlling ( 16 )

what happens when someone moves the shifter inside the car?

if it is in gear one of the forks controlling ( 15, 16, 17 ) then is about 5-7 mm left or right from the just now position.

I´m just rebuilding a gearbox again here as a reserve gearbox and will make later photos of the forks how it looks when 1 gear is inside.

 

here is now second gear in ( from the forks, no gears inside )

sorry mistake: not 5-7 mm, it is 9 mm Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
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hope this helps a little?

 

If the trans was stuck in two gears the car wouldn't move. The detents and balls on the shift rods prevent the selection of 2 gears at once. If the car shifted fine before, and the gearbox was not opened, then your problem quite possibly could be in the external adjustment and external shift bushings?

 

I'd focus on the shift shaft connection. When I put mine back together it was all a mess. I didn't have it tight enough and it would move when I went left and right on the shifter. With these cars always diagnose the easy stuff first. You have hours into this and probably delved too far into a procedure you really didn't need to go into.

 

Romano, Is that heavy paint inside your photos of gearbox? Mine didn't look like that.

 

If the fork for second is truly in neutral with the cone clutch disengaged, then possibly second gear is froze on the main shaft.

 

david
this is a nanoseal coating, 2 compound, heat and oil resistant. I try this now 1st time. before I used other ( color has been like brown as it was original ) but this is not longer available, no more allowed in the EU

the older aluminum cast has been like a sponge and with this coating no oil is leaking anymore - I hope so

Billy: as I have written in post 11 I see that the sleeve for 2nd and 3rd gear is not in the middle as for neutral, it seems to be connected to the 2nd gear because to much space to the synchromeshring form the 3rd gear. could you please make a detailed photo from the fork for the 2nd and 3rd with the sleeve and also to see the distance the sleeve has to both gears. so 3 photos please: 1 in neutral, 1 in second gear and 1 in third gear.

you write it select all gears. so the idea from david could be true, that the second gear is froze with the main shaft. this I never had before, only the 3rd gear for the reverse once I had blocked on the shaft. but when you then can shift into for example 3rd gear and as you have written this shifting will work, then the gearbox will block and not move anymore, but you still always drive in 2nd. very strange all

 

misstake: the 2 loose gears for the 2nd and 3rd are moving on the lay shaft, not the main shaft.

 

Okay, first you need to determine which gear is turning the shafts. While in neutral, try and turn the engine with a socket on the front pulley or use a bump over switch connected to the started (I would use the bump switch to diagnose). If (as it looks in the picture) the shift mechanism is actually in neutral, then one of the gears has seized on the shaft and is driving the trans without being engaged.
While I have never seen a gear seize on the shaft, one thing 25 + years of working on Ferrari has taught me, just because you have never seen that issue does not mean it is not happening. If the shift sleeves are in the neutral position and from your neutral picture they appear to be, then something has seized the gear to the shaft. I have build many Boxer/TR trans and the gears are all on flat roller bearings. Like I said though, that does not mean they are functioning correctly.
Also, I am happy to speak to you over the phone and help you go in the right direction, as I said, I have had many of these apart.
770-845-8335.

 

thank you very much for those photos. it seems all ok.
so as wade has written, have a look what gears wil turn when you turn the crankshaft from the engine. but it will be har dto do this because all gears are turning.
but also you may try the following:
one has to stay in the car and push the clutch, gearbox in neutral, the other will try to turn the loose gear on the lay shaft 3rd gear: then the wheels may not move but the mainshaft will move, that is why to push the clutch. same you try with the loose gear 2nd gear. and again the wheels may not move.
but as you tell the 2nd gear is always in, so then if you will turn the 3rd gear the wheels will move and also when you turn the 2nd gear.
but what I wonder: if there is in 3rd gear and ( good to see in the photos) then the 2nd gear can not be in. and if the gear is froze in the bearing then the gearbox would block. very strange all I only can say.
when you put in 3rd gear, you did this with the shifter inside or directly at the gearbox? I ask because at the beginnig you told us that you only can shift in 2nd, neutral and reverse.