Specialist Ferrari 360 Gearbox Transmission Workshop Service Repair Manual – PDF Download

0 GENERAL INFORMATION

C6.02 ENGINE PARAMETERS DISPLAY C6.03 ERROR SIGNALS C6.04 ACTIVE DIAGNOSIS C6.05 AUTOMATIC CYCLE D CLUTCH-GEARBOX-DIFFERENTIAL D1 GENERAL SPECIFICATIONS D1.01 TECHNICAL FEATURES D1.02 SPECIFIC TOOLING D1.03 COMMERCIAL TOOLING D1.04 TIGHTENING TORQUES D2 DETACHING THE ENTIRE GEARBOX- DIFFERENTIAL UNIT D2.01 DISMANTLING D2.02 RE-ASSEMBLY D3 CLUTCH D3.01 REPLACING THE COMPONENTS D3.02 CLUTCH PEDAL STROKE ADJUSTMENT D3.03 CLUTCH CONTROL HYDRAULIC SYSTEM D3.04 SYSTEM BLEEDING D4 GEARBOX D4.01 REPLACING THE EXTERNAL COMPONENTS D4.02 REPLACING AND ADJUSTING THE CONTROL CABLES D4.03 REPLACING THE GEARBOX LEVER HOUSING D4.04 DETACHING/RE-FITTING THE GEARBOX SUPPORT MOVABLE FRAME D4.05 GEARBOX OVERHAUL D5 DIFFERENTIAL- AXLE SHAFTS D5.01 REPLACING THE COMPONENTS D5.02 AXLE SHAFT D6 ELECTRONICALLY-CONTROLLED GEARBOX D6.01 INTRODUCTION D6.02 GENERAL FEATURES D6.03 TRANSMISSION CONTROL UNIT (TCU) D6.04 OPERATION D6.05 HYDRAULIC SYSTEM D6.06 POWER UNIT D6.07 ACTUATORS D6.08 MEASURING SENSORS AND SIGNAL SWITCHES D6.09 SIGNALS AND CONTROLS D6.10 SYSTEM FUNCTIONS D6.11 REPLACING THE ELECTRONIC CONTROL UNIT (TCU)

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D1.01

TECHNICAL FEATURES

Longitudinal mechanical transmission with synchronized six gears and reverse gear.

The manual control lever is situated in the centre of the tunnel. In the electrically controlled version, the equalizer control levers are situated behind the steering wheel.

The gearbox housing, besides the main and lay shafts and the coupling forks, also contains the bevel gear pair and the self-locking lamellar differential.

The engine oil tank is machined in the gearbox housing's monolithic cast.

The synchronisers for 1st and 2nd speeds have a triple cone while the others have a double cone.

The lubrication of the gearbox gearing, which is the same as for the differential's, is carried out by a volumetric pump with concentric gears, operated by the auxiliary mechanism of the reverse gear.

The temperature of the gearbox/differential oil is adjusted by an oil/water heat exchanger, placed between the water head outlet manifold and the water pump.

The clutch is the dry monodisk type, with flexible couplings and diaphragm springs.

The clutch is released by using a self-adjusting thrust bearing (A). The thrust of the fluid within the hydraulic circuit makes the bush bearing holder (B) slide onto the flange's sleeve (C), until the clutch is released.

Gearbox Ratios

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Gears 1a 2a 3a 4a 5a 6a RM

Gear ratios 46/14 = 3,286 41/19 = 2,158 37/23 = 1,609 33/26 = 1,269 30/29 = 1,034 28/33 = 0,848 41/16 = 2,565

Final reduction ratio (engine rpm/wheel rev.)

14,603 9,591 7,150 5,641 4,598 3,771 11,389

Bevel gear differential ratio: 40/9 = 4,444 Gearbox features End float: – main shaft neutral gears – lay shaft 1st and 2nd speed gear – between seeger and lay shaft bearing, on the plate – Reverse idle gear Backlash Pinion bearings' rolling torque housing) Interference of double gear assembly on lay shaft: – 3rd and 4th – 5th and 6th

0.10÷0.30 mm 0.15÷0.25 mm 0.03÷0.05 mm 0.125÷0.325 mm 0.08 mm 1.5÷2.3 Nm (before assembling on

0.04÷0.06 mm 0.03÷0.05 mm

Gearbox/differential rolling torque (detected on clutch shaft with completely assembled gearbox):

Engaged gear N 1st 2nd 3rd 4th 5th 6th Reverse

Clutch Specifications Brand External diameter of gasket Internal diameter of gasket Thickness of clutch disk loaded (7400N) Clutch disk wearing limit

VALEO 247 mm 165 mm 8,3 ± 0,3 mm 0,8 mm

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Rolling torque [Nm] from to 0,6 0,8 1,8 2,1 2,5 2,7 2,8 3,4 3,6 4,5 4,4 4,8 5,7 6,2 2,7 3

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Flywheel Specifications Distance of working surface to clutch disk/keying surface to crankshaft Maximum reduction in working surface thickness Surface roughness Maximum flatness deviation on working surface

22,9±0,15 mm 1,0 mm 1,5 – 3,5 µ 0,05 mm

Hydraulic Thrust Bearing Specifications Working surface Maximum stroke Auxiliary spring pre-load

709,2 mm² 14,6 mm 73,5±3,9 N

Differential features Differential type Reduction bevel gear pair Reduction ratio Pre-load adjustment Support bearing type Differential slipping torque Differential housing rolling torque

Self-locking, lamellar Spiral (GLEASON) 9 : 40 By spacing washers Tapered roller 48÷75 Nm 3÷4 Nm

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Pinion/Crown backlash (on 3 points at 120°) Self-locking percentage in tension Locking percentage when released

0.13÷0.18 mm 30 % 50 %

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D1.02

Tool n°

SPECIFIC TOOLING

Description AV 2714 Extracting tool AV 3045 Pins for extracting tool AV 3048 Box wrench for hydraulic clutch control's stud bolt AV 3070 Tool for clutch disengagement AV 3075 Punch for driving flexible pins onto the bearing holding bushing AV 3079 Punch for centering complete thrust bearings AV 3080 Thrust bearing centering tool AV 3218 Tool for fitting the seal ring (3 pieces) AV 3219 Tool for replacing the gearbox housing's upper flexible bushing (4 pieces) AV 3375 Tool for replacing the gearbox housing’s upper flexible bushing AV 3234 Tool for replacing the gearbox housing's lower punch (8 pieces) AV 3243 Tool for fitting assembled gearbox shafts (5 pieces) AV 3244 Gearbox housing's closing flange for checking the rolling torque AV 3245 Key for fastening the main shaft ring nut and check ring nut AV 3246 Key for fastening the main shaft shoulder ring nut AV 3247 Key for ring nut retaining the lay shaft's bearings AV 3248 Support for gearbox housing AV 3251 Centering screws for forked shaft-rod cluster AV 3252 Tool for disassembling/assembling the main shaft (4 pieces) AV 3255 Tool for assembling double gearings and bearing on the lay shaft (4 pieces) AV 3257 Kickback tool for lay shaft ring-nut tightening AV 3258 Tool for fitting the clutch shaft's ball bearing AV 3259 Tool for fitting the roller bearing's outer ring AV 3260 Tool for extracting/inserting the gearbox housing's bearing (2 pieces)

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AV 3536

AV 3261 Tool for fitting the clutch shaft's bearing AV 3262 Tool for fitting the spacer and the 1st and 2nd speed synchroniser body AV 3263 Tool for various fittings on the lay shaft AV 3264 Tool for fitting the ball bearing on the main shaft AV 3265 Tool for fitting the bearing and the bushing on the intermediate plate (4 pieces) AV 3266 Tool for testing the pinion play AV 3267 Tool for fitting the ball bushing AV 3268 Punch for fitting the retaining washer (Ø 14 mm) AV 3269 Punch for fitting the retaining washer (Ø 18 mm) AV 3270 Puncher for fitting the retaining washer (Ø 25 mm) AV 3271 Tool for positioning the gear shift control lever on the rod AV 3272 Extractor for 3ª - 4ª speed synchroniser on the main shaft AV 3273 Tool for extracting the forked shaft-rod cluster AV 3274 Bushing with bearing dimension AV 3275 Tool for fitting the ball bearing's outer ring on the differential cover (2 pieces) AV 3276 Tool for fitting the bearing on the differential's semishaft with right-hand side flange (2 pieces) AV 3277 Tool for fitting the bearing on the differential's semishaft with left-hand side flange AV 3278 Tool for fitting the differential's tapered bearings (2 pieces) AV 3283 Union for gearbox pressing AV 3284 Tool for testing the envelope between the bevel gear pinion and the bearing's seat AM 106121 Tool for fitting the synchroniser components AM 106628 Tool for locking the differential CS 106524 01 Tool for checking the distance between the pinion and the bearing's seat USAG 815 F Electric torque wrench with controlled grip Locking plate for pressure seal test

WARNING Tools without hand protection must only be used with the press.

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D1.03

COMMERCIAL TOOLING

Article

Description

FACOM U.53J2 FACOM R.250A

1000 BULLES USAG 454N/2 USAG 815 F USAG 454N/3 USAG 468S11 Art. 154

ZO-PW 470

Series 460 Art. 5184TC500

F250

Set of bearing extractors Torque wrench End of scale: 2รท9 Nm Leakage detector of gases Armed extractor Torque wrench End of scale: 250 Nm Armed extractor Boxed assortment Press Capacity: 10.000 Kg

Calibrated blocks

Electronic surface gauge Usable length: 500 mm Reading: 1/50 mm Precision: 0,05 mm Forced ventilation kiln

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Manufacturer FACOM

AIR LIQUIDE USAG

CORADE S.p.A. via Pietro Toselli, 81 50144 (FI) Tel. 055 32271 ATS FAAR via Camporicchio, 1 20060 Vignate (MI) Tel. 02 95360013 r.a.

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D1.04

TIGHTENING TORQUES

NOTES To check the tolerances in relation to the tightening category (

02.05).

Description

Nm

Nut and screw fastening gearbox to engine

56

A

Nut for screw fastening lower part of gearbox

75 21

B A

8

B

49 18

A

Clutch pipe union Screw fastening r.p.m. sensor Gearbox oil cooling pipe union Screw fastening crown wheel Screw fastening pressure plate Screw fastening flywheel Nut fastening clutch cylinder Pipe union for clutch pump Screw for flange supporting thrust bearing bush Support screw with anti-rotation pin guide Stud bolt fastening flange for thrust bearing bushing support Union for oil pipes on box Union on oil pipes Bleeding union

18

Category Product

A

91

A

20 18 25

B A A

1,2

A

18

A

18

A

21 18 15

B A A

Fastening screw on union block Screw fastening right flange cover Screw fastening differential cover Screw fastening gear-selection and shift lever Lock-nut on ball joint Screws fastening gearbox turret Screws for fastening cross member to frame Screws for fastening frame to chassis Screws for fastening frame to gearbox Screw fastening axle shaft (preload 40Nm)

10 30 27 7,4 25 9,8 28,5 98 78

Screw fastening gearshift lever onto the rod Nut fastening cover with control rod Nut fastening gearshift/selection actuator

32 7,4 10

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Arexon 4706 System 52A 43

A B B

B A A

MOLYKOTE 1000 grease

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Nut fastening ball joint to gear selection and engagement 7,4 levers 10 Fastening screws for lubricating nozzle Screw fastening bushing bearing holder Screw fastening rear cover Ring nut and check-ring nut on main shaft Shoulder ring-nut on main shaft Bushing fastening screw Oil pump fastening screw Screws fastening bearing plate holder Rear ring nut for the main shaft

B LOCTITE 270

30 30

LOCTITE 270 LOCTITE 242

100

LOCTITE 242

70 8

LOCTITE 242 LOCTITE 270

4 30 100

300 Ring nut fastening tapered roller bearings on the lay shaft Nut and screw fastening actuator supporting bracket and 24 guard 22 Connecting pipe unions for the gearbox-actuator Power Unit 24 Nut fastening oil pipe supporting bracket to gearbox housing 7,4 Screw fastening pipe holder mount to framework

LOCTITE 242 LOCTITE 242

B

B B

Screw fastening clutch sensor to support

0,9

B

Nut fastening Power Unit bracket to chassis Nut fastenign clutch locking block

7,4

B

7,4 7,4

B A

Fastening nut supporting Bowden cables

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Arexon 4706 System 52A 43

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D2.01

DISMANTLING

This paragraph describes the dismantling procedure of the entire gearbox-differential unit from the car. This procedure is necessary in case of overhaul or complete replacement of the gearbox or in case of repair work that cannot be carried out with the gearbox installed in the car.

NOTES The procedure and the figures refer to the disassembly of a electronically controlled gearbox. The disassembly procedure for a mechanically controlled gearbox is similar, for this reason only the differences are illustrated.

Procedures The gearbox-differential unit must be lifted from the engine compartment. To carry out this procedure it is necessary to use a movable hydraulic hoist or a bridge crane with 200 kg minimum capacity and two safety belts to sling the unit.

IMPORTANT Before starting procedures within the engine compartment, adequately protect all the polished surfaces of the car body and chassis. • •

Drain the engine oil ( Remove:

A 3.01).

- the engine compartment boot (

M 2.01);

- the side protection guards of the engine compartment ( - the complete soft top unit (

M 2.13);

N 2.01);

IMPORTANT FROM the vehicle Ass. No. 41464, the gearbox-differential unit can be removed without having to lift the top unit. This is possible because the new top housing bays are equipped with openings which provide access to the fastening screws of the side frame supporting the gearbox. Such screws can therefore be removed without lifting the top.

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- the rear part of the underfloor (

M 2.12);

- detach the axle shafts from the gearbox ( M 2.04);

- the rear bumpers (

F 3.06);

- the rear wheels ( - the rear wheelhouses (

- the coolant expansion tank ( - the air intake (

D 5.02);

M 2.05); B 5.05), keeping it connected to the system;

B 7.03);

- the exhaust silencer with its support and joints ( - the catalytic converters ( - the gearbox support frame (

B 7.07);

B 7.06); D 4.04).

NOTES To avoid excessively unbalancing the weight of the engine-gearbox unit towards the rear and straining the engine support pads, it is advisable to position a rubber pad of the suitable thickness under the gearbox, between the box and the chassis beam. •

Detach the oil radiator pipes from the blow-by system and from the stiff pipe on the

engine (

B 4.04); fit the stiff pipe (A)onto the engine.

Electronically controlled version only • Detach the F1 harness from the connectors (B) for the clutch and gearbox position sensors, on the RH side of the gearbox housing.

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Electronically controlled version only • Detach the two gear engagement-selection position sensors from the F1 harness (C), located next to the clutch pipe union.

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• Remove the gearbox protection guards (D) for the gearbox revolution sensor along with the actuator protection, by detaching them from the bracket on the gearbox housing.

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• Detach the actuator's rear support bracket (E) from the gearbox, by unscrewing the two fastening nuts.

• Unscrew the eight Kylock nuts which fasten the actuator (F) to the gearbox housing.

• Detach the actuator from the gearbox housing, leaving it connected to the Power Unit.

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• Detach the oil pipes connecting the gearbox to the exchanger, unscrewing the screws (G) of the filler neck unions.

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• Release the oil pipes from the support bracket (H) where the nut fastens the blowby system to the gearbox housing.

• Detach the blow-by system's piping (L) from the oil separator.

• Remove the r.p.m. sensors (1) on both sides of the gearbox ( C 2.02), keeping the cable fastened to the head and connected to the injection harness.

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• Working from under the car, detach the engine service cable (2) from the starter motor, from the oil engine temperature sender (3) as well as from the brackets (4).

NOTES To avoid contact between the starter motor and the chassis rear cross member, it is advisable to also remove the motor (

L 2.04).

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• Unscrew the clutch pipe union (5) from the block (mechanical gearbox only) and disconnect the support clamp (6) of the radiator oil delivery pipe from the bracket.

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For mechanically controlled gearboxes only • Remove the joints (7) of the Bowden cables for the gearbox control from the transmission levers.

• Unscrew the nuts (8) fastening the cable support to the gearbox; remove the support and the cables from the gearbox.

•

Detach the lower connecting rod (9) from its fastening on the gearbox.

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• In the lower part of the engine, unscrew the screws (10) fastening the lower part of the gearbox to the engine.

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• Unscrew the six nuts (11) fastening the gearbox to the engine, keeping the support brackets.

Lifting IMPORTANT To keep the engine in its position, without straining the pads, it is necessary to use a hydraulic hoist to support the engine or to insert two 55 mm shims between the exhaust manifold and the chassis.

• •

Introduce a pivot (M) into the hole of the gearbox upper support.

Pass each belt under the axle shaft flange connection and behind the pivot (M).

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•

Fasten the ends of the belt onto the hoist hook.

CAUTION For safety reasons, the above-mentioned position of the belts must be respected.

• Lift the gearbox until the belts are tensioned.

• Pull back the gearbox by sliding it off of the engine stud bolts and of the shaft internal coupling on the clutch disk.

NOTES In case of difficulty in making the shaft spline come out of the clutch disk, pound the coupling area of the two cast-pieces with a rubber hammer. Absolutely avoid prizing the coupling surfaces with metal objects.

• •

Slowly raise the gearbox, avoiding contact with the chassis.

Position the gearbox-differential unit onto an adequate support.

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