My 355s clutch replacement adventure

Last season the clutch starting to slip on my 95 F355 (33K miles). After some investigation, I notice a slight leak of fluid from the bell housing area and suspected a leaky seal somewhere with the input/output shaft and throwout bearing.

Contemplating a $3K plus bill to have it replaced by someone else, I decided it was time to take on the maintenance of this car. After quite a bit of research on how to fix this problem and Jonathan Bird offering up the use of his new garage and lift, I pulled the trigger and bought a new clutch and throwout bearing assembly (I was told TO assembly was of an updated Ferrari design). $1700 and some time later, the day finally arrived to tackle this project.

With the help of Johnathan Bird, Verell, John Beauche, Scott Major and Jay O we got the car on the lift (required the removal of the rear air diffusers) and under an hour had the air boxes, heat shields, bumper, muffler, and wheel well covers off the car and the bell housing exposed. The next hour was spent trying to seperate the bell housing cover. This was tough due to the fact that I doubt this has ever been off the car since it was assembled, so we has a little aluminum corrosion to contend with. Verell worked the pry bars and with the PB Blast got the cover to finally release. Once the cover was off we could see fluid and clutch material all over the inside of the bellhouse. Upon invesigation we discovered the throw out bearing was leaking on its thrust flange (and spinning all over the clutch plate causing it to slip).

To make a long story short, the replacement was straight forward enough except for there being no directions on how to assemble the seals inside the bore of the new throwout bearing which was different that the one that came off the car (the new design has more seals than the original). Then there were two holes on the side of the throw out bearing thrust flange that need to be plugged with an included aluminum bolt. (You thread the bolt in enough to close the hole but keep the passage below it clear, then cut off the excess and peened the head down). During the first time we put the car back together we only noticed one of the holes, doh! I also want to mention thre new parts didnt include some key seals that just made sense to replace while we were doing this service. After a trip to Ferrari of New England to get the missing parts (kudos to the parts manager, Mark, who went above and beyond to help us, had everything in stock and turns out to be *VERY* competitive on part pricing). Once we had everything we needed and we figured out the position of the new seals, got the clutch and pressure plate aligned *WITHOUT* an alignment tool (good work John B!) and filled all the holes in the flange. The job went pretty well. For those that attempt this, I highly recommend pressure testing and bleeding the system before bothering to but the muffler and bumper back on.

Thanks guys for all of your help! Special thanks to Scott, who stayed with me until after midnight, and was a huge help in getting the car put back together (twice). I also need to thank Verell and Jonathan for their patience. They waited until we were finished with my 355 to paint the doors on Jonathan's Mondial which they had hoped to do much much earlier.

-Michael

 

Michael,

It was truly a pleasure working on the car with such a great bunch of people. I must say that working on this component of the 355 drive train is very easy and straight forward. If you can turn a wrench you can do this. I am confident that had the entire kit been there from the start we would have finished well before dinner. Sorry for getting a little punchy there at the end.

To Johnathan, John, Verell and Jay O. Yesterday was a great day. Thank you for all for the laughs, eats and downright good time. I look forward to getting all of you on the track at somepoint this summer. So Jay, when are we gonna tackle that rear main seal? (thanks for the ride yesterday too!)

Also, if anyone who reads this plans on doing their clutch this summer instead of paying a shop to do it ask me (or anyone here) for help. Having done it twice yesterday I am feeling very confident on doing this again.

Thanks again guys! I got to make some new friends and had a great overall learning experience.

p.s. Hey Johnathan, where are the pics from lunch?

Scott

 

Stand by....they're still in the camera....I'll get on it!

Birdman

 

OK, here we have some pics.

First pic, the crew, except me and Jay (L to R) John, Verell, Michael and Scott.

Next, lunch is served...on the trunk of the Mondial. (Don't worry, we put a towel under the pizza.) Jay and Scott are hungry. Stand back!

Next pic, the ultimate pizza server...a Ferrari. And if you start the car, it keeps it warm too!

Finally, a Ferrari garage event always has a few Ferraris. The pizza guy asked if we were starting a Ferrari repair shop...and he was serious! (I thnk the zoning board might have something to say about that....)
Birdman
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Hey Michael...great post!! I guess it could only help to have a crew like yours, and a garage like THE Birdman's. I'm all alone over here, but I'm getting ready to do the same job on my 1999 F355 Berlinetta. Did you use the Hill Engineering throwout bearing? Also, is it possible that you could list the "key seals" that you got from the Ferrari dealership. I'd like to benefit from your experience by taking care of those myself as well "while I'm already in there".

 

Nice work!!! I did mine about 4 yrs ago in the garage, that was the first maintenance I had tackled on the 355. As you said, not bad at all...just another reason to not trade in for a 360