We often pick on people who say “all you gotta do is”, because there’s no such thing as “all you gotta do is”…. Anyone who says “all you gotta do is” either has never done it before or is trying to beat you up on an estimate. AKA, a looser

Most of the cars we work on have brand new brake components available to purchase which allow us to slam ‘em in and ship it. Unfortunately, we have to rebuild brake components on Ferrari’s which really sucks.  All you gotta do is…  Ugh. A guy sent me a totally blown out Master cylinder for a 330 GTC, rusted and stuck, terrible, horrible, so I sent steel fittings off to be cadmium plated, sent the cylinder to have a new sleeve installed in the bore, ordered an overhaul kit and when everything returned, I put it all back together. After assembling it the I noticed that the pistons were sticking in the cylinder so I took it all apart and the wrenches scratched the fresh plating and watched as the brake fluid stripped the black paint. I honed the bore and got the pistons to move freely, assembled it again and set it up to be tested on my high tech device that you can observe in the photo below. Now I am finding that the sleeve wasn’t drilled correctly and fluid couldn’t  into the forward chamber (that goes to the rear brakes) so I had to start all over again, scratching, chipping. Now, the cylinder is all back together and working perfectly after 7 hours of labor! “All you gotta do is”! Did I mention that the rebuild kit didn’t come with the correct first seal, there was a 30mm seal included when I needed a 25mm seal so after buying 3 kits, I resorted to making my own seal.

Ferrari GTC Brake Master Cylinder

If I were making a production run of something, this isn’t how I would do it. Ferrari made thousands of “250″ series cars all with these goofy water pipes for the cooling system which vary drastically throughout the 10 year production run.  They are so complex and hard to duplicate that re-making them nearly impossible. This “J” shaped pipe has a compound curve with barbs that have to be welded on in exactly the right location even though they appear to be stitched on at random locations. If they are off one millimeter, they will hit the oil filter or run into the fan.

These pipes are for the Lusso/GTE series of 250, but I can make a number of other styles from 166 up through the 275 cars utilizing my incredible and growing stockpile of bends and flared ends. Right now I am making a short run of the water pipe that connects the thermostat housing to the engine on a 275 GTB/GTS Two-Cam engine.

Water pipe for Ferrari

Water pipe copied for Ferrari

I don’t offer much helpful information on this blog but want to share some photos of the font and progression of transmission, engine, and axle number stampings on Ferrari castings. From now on, i’m going to photograph stamps on Ferrari castings as I have the ability, the transmission stamps are hard to photograph because the interior has to come out for access. These are all photographs of Transmissions from 250’s and 330’s.  As things progress, I will post photos of Engines, axles and trans-axles.

Numbers from early 330 with Overdrive

Series II PF Cab, late production

Early production GTE Ferrari

Transmission Ferrari Lusso 2505-speed 2 mount engine

We rarely have to repair rear axles and usually just clean and inspect the bearings and install new oil seals. Be it a Jaguar, Chevrolet or Alfa Romeo, it is rare that we see a ring and pinion that is damaged or bearings that are worn out. I hate to disturb the factory relationship between the ring and pinion gears so if the bearings check out ok, I keep the thing together.

Additionally, most car companies have figured out how to make the final drive robust and problem free because they are aware of the forces involved with the ring and pinion bevel gears – except for Ferrari. They used a deep groove ball bearing and sliding inner race roller bearing that cannot handle the axial loads on the pinion shaft. Other companies used tapered roller bearings that can handle a tremendous amount of this fore-and-aft thrust while spinning with ease but the Ferrari style comes apart and destroys the gears.

My solution is to replace the sliding inner race roller bearing and the deep groove ball bearing with a pair of tapered roller bearings. This photo is a 250 GT Lusso center section with the “chicklet” style limited slip differential. On some axles I’ve install tapered roller bearings to support the differential but on the later axles there isn’t much room to install this type of bearing and I have found the original ball bearing set up to be adequate. I have done this conversion to many cars that have gone many thousands of miles with no issues.

Final drive Ferrari

GT Ferrari 250 Axle Center section

After overhauling dozens and dozens of Ferrari transmissions I have a good idea on what to expect when the case is opened up and shafts are broken down. Whether it’s a 250 GTE 4 speed, a 246 GT Dino trans-axle or a 330 GTC/Daytona style 5 speed trans-axle,  synchronisers on Ferrari’s do not last many miles however, the rest of the components are over built and hold up well.. The bearings and gears are over built and the machined parts like flanges and shafts are impeccably machined using incredibly hard steel. The transmissions have oil pumps that pressurize the main and lay shafts to keep everything thoroughly lubricated so the bearings that the gears turn on are flooded in a pillow of oil.

This transmission out of this 250 shifted well but had the typical severely worn synchronisers so I was prepared to perform the “normal” repair of cleaning, inspecting and replacing the end bearings and synchros. This trans had been run without oil for a long time and the bearings in the photo were so wiped out that there was about .020″ clearance between the gear and bearing where there should only be about .005″. How did this thing work at all?

250 GT transmission overhaul

Transmission overhaul bearings

Bearings Ferrari transmission

Here are some more photos of the GTE transmission that I am overhauling. Everything else looks fine inside, we are replacing all of the bearings and synchroinzer bands. The main shaft and lay shaft gears are all in excellent condition.

Transmission

Gears for mainshaft and layshaft

but the gears and spacers are all good.

Last month we removed the transmission on a 250 GTE to have the overdrive that was inoperative inspected and rebuilt. When our friend John returned it to us, he mentioned that the filter on the overdrive was packed with metallic fragments that must have come from the transmission since nothing metallic matching this debris came from the overdrive. He told me that without removing, inspecting and super cleaning the transmission, there is no way the overdrive would last more than a few thousand miles.

I could not imagine what could have been a problem since it shifted well and was quiet when I drove the car prior to the tear down.

Yesterday I began to take the transmission apart and found that the Boccola ingranaggio, or 1st, 2nd and

250 Transmission gear

Bushing for 2nd gear

3rd, gear bushing style bearings are all torn up and the lead/tin coating has been wiped off the surface, probably from a low oil condition. I bet there was a pound of metallic sludge in that overdrive brass screen filter.

Here is what thousands of hours of detailing a Ferrari Lusso engine looks like. It is dusty and not totally finished but getting close. If I had a driveshaft I would take her for a spin! Really looking forward to driving the car because we did some enhancements to the engine and installed a overdrive transmission to make the car that much better and faster.

Engine to the Lusso

Here is what amounts to about $5000 in labor, the front suspension on a Ferrari 250 completely overhauled and detailed.

New pins and bushings, proper finishes and hopefully it will look this good for more than a few years!

90,000 miles on a Ferrari

Cleaned up, overhauled and detailed