Linkage Adjustment or bent shift fork?

New to Ferrari chat, in fact new to Ferrari period. Recently purchased 512TR (which was my dream car since forever). Anyway, yesterday, I was giving the obligitory rides to family when the car jumped out of first while under acceleration. Was able to pick up second, third, fourth and fifth, however, when I came to a stop, the car went into the gate for first a little loose, and would not engage the gearbox. Also had trouble putting into reverse (came in way early) and would not release until I backed it up. Experience tells me that I have lost some throw on the first to reverse actuator, however, since I have not had this car apart (and have no manuals for service) I did not want to start adjustng without advice. Clutch is sound, can drag in fourth without slip or chatter, and once under way it shifts from 2nd to 5th fine. Any advice? Car has 26K miles and is a 92.

Rod

 

Its OK Rod, your new to this forum, and new to Ferrari ownerhship. Perhaps all those that looked at your post were not 512TR familiar. Any way, continue pulling the exhaust and CV joints tomorrow morning to access the linkage housing and main gear dogs (forks). You have always figured out things on your own anyway, and perhaps being part of a community is not so important.

 

Phillip, thank you for the response. Unfortuantely, I cannot get the car out of first, and rather than risk breaking anything, I decided to access the side cover. I have read every post regarding transmission/shift issues and hoped to glean some knowledge, however, it seems that most talk is around the 3x8 models and not my 512TR. For any one who is interested, accessing the 512TR shift forks is not a simple task. Seems Ferrari modified the tranny mount after lowering the engine in the 512TR-M series, so you must remove the forward motor mount. In order to remove this mount, the driver side exhaust must come off, as well as the CV joint. You are probably correct about the linkage adjustment, but just getting to it is a mission in and of itself.
Rod

 

Thanks for the reply Ferrarifixer. The reason the driver side CV had to come loose is that I could not access the third exhaust manifold bolt. Regardless, after all was removed, I pulled the access cover off of the side of the tranny and there was no need to look at the condition of first gear, as it fell out in three pieces in my hand. So, this project is obviously going much further. Yes, I am now one of those guys that only owned a Ferrari for three days, drove it 250 miles, and now have a major repair. I guess those stories are not really urban legend after all.

What I find striking is that the gear that broke showed no obvious signs of distress, nor does the upper shafts/bearings look hot, the fluid smelled fine and there is oil all the way to the top of the case dripping down. I also find it striking that the car was under acceleration when the gear broke, not between gears nor leaving from a complete stop.

Anyone else had this experience? Guess I will be Ferrari running gear conversant before too long. BTW, the gear box shows no evidence of ever being opened up, and the car recieved 2K miles per year over the last 5 years, so I have ruled out garage queen failure and mischevious intent from the previous owner. Guess the belts are the least of my worries now.

Rod

 

Thnaks for the post Daniel, and the parts pictures. I have a service manual on the way, will begin engine removal this afternoon. Looks pretty straightforward to me, however, I am unclear of the attachment points on the block I should use when lifting. Since the subframe is welded on the 512TR, others recommended pulling out from top, and I concur. Further, it appears I should probaly remove the intake runners, but perhaps no?

Any advice, and of course parts availability when I get the list together, would be helpful.

Rod

 

Thanks for the response guys. Glad to know (I think) that I am not the only one with a 512TR gearbox issue. Ferrarifixer, it appears you are well versed in running gear R&R, can I contact you for advice as this project progresses? The manual I have (740 pages) appears specific enough, giving me gear load tolerances, synchro check specifications et al, but any "hands on" experience would be helpful. I should have the running gear out by tomorrow afternoon, the tranny pulled down the next day. Believe it or not, on monday, 7/11/05, I am flying to Italy for a vacation. Will be there ten days, maybe I can source parts locally and save a little freight.

Side note: Drivers side CV does not want to retract far enough to swing out of well in transaxle. I don't have to let the A-arm loose and swing the hub out do I?

Rod

 

Thank you Jeff, I will likely take you up on that. Daniel, my last trip abroad I believe declarations were over 10K. Has that changed? Also, does customs give you stink eye on car parts?

 

OK Ferrarifixer, motor out, and tranny will be disassembled by end of day. Am working with Jeff who posted above, he has rebuilt several 512TR gearboxes (which were mostly under warranty back in the day, alas, not so mine) but would like to keep you in the loop. Is it possible to forward you pics via email? I know you are half a world away, however, the more eyes the better.

Thanks, Rod

(side note, any Ferrarichat members that would like a blow by blow of this repair I would be happy to forward all info/pictures as we progress. I think posting here in the forum would get quite lengthy, and probably very boring) All info points to a known 512TR problem, improper heat treating of first gear. These usually broke within 1-2k miles of new, so most were fixed under warranty, however, mine decided to hold out until precisely 26, 973 miles, at which point it was my turn to become a gearbox technician. As the saying goes, two weeks ago I could not spell Ferrari Mechanic, and now I is one.

 

First pic. This is what first gear looks like when it come apart. Surprisingly, it did not explode nor damage (at first look) the lower gear. It simply split into three pieces. (whoops, don't know how to post pictures, upload manager says they are too big. Any advice?)

 

OK, here are the first pics. Do not know what anyone elses experience with the 512TR first gear issues are, but I was extremely lucky (well, sort of). My first gear broke into three equal pieces and was laying up in the shaft. I removed the oil pump and the fluid and oil pump gears looked like new. There were absolutely no filings in the corners of the gearcase, and no chunks in the fluid. So, even though the tranny is completely dissassembled, the only parts needed (or so it appears today) are first gear and its mating gear. Jeff, who posted above, has been a godsend. He told me that most 512TR's that had the metalurgical issue with first gear (not hardened properly) were repaired within the first 1000 miles of service. He himself did 5 in one month back in 93. They guys knowledge is incredible, and he has been just a prince! He is starting his own private shop after 23 years of Dealer employment, and by all means, work with him if possible. He is located in Kansas City, central to jsut about everywhere. Any way, take a look at these. Ferrarifixer, you ever seen this type of break?

Rod
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Thanks Ferrarifixer, off to Italy tomorrow, going to be at the Ferrari facotry next Friday. I'l have a talk with em about there QA system as they toss me out the door.

 

Back from Italy, tear down complete, parts ordered. Look at the pic below, the shaft splines not only wore, but the end splines on the input shaft are twisted. Ferrarixer, ever seen this on top of the split gear pics I posted before? BTW, I want to make a big, public thank you to Jeff McKormick, who posted above. I am not here to sell him nor his services, but I want all to know that I have only driven a ferrari (first ime in my life) for a total of 6 hours, and have put in (to this point) over 45 hours labor on the gearbox alone. Of course, belts and valve adjustment will be done while motor is out, but that is minor comapred to gearbox rebuild. I could not have (well maybe I could but a lot slower and for a lot more money) made these repairs without Jeff and his constant input. We speak almost daily now, and I can say I have never met a more pleasant individual in my life. I could be soured on this car, however, Jeff has been so patient and kind he has made this enjoyable. That is, I think, part of why I am gonna love this car when it hits the road next week. Part of a community of people who like unique cars.

Rod

 

Try again to post the picture of the shaft.
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