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The real cost of a 512TR DIY Major Service

Discussion in 'Boxers/TR/M' started by JIMBO, Jun 5, 2020.

  1. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    Bradenton, Florida
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    Jim DeRespino
    Well, the major service is done and the mighty 512TR has now passed 200 miles with no problems, so hopefully all is well. No noises, no leaks, all 12 cylinders firing. And it only took 7 months. As promised, here is a real world break down of the cost to Do It Yourself.
    Now, I went a bit above and beyond, replacing the radiators, changing to gold connectors, new AC compressor, fuel pump kit, etc, so all those will be subtotaled separately. I assume you have the necessary basic tools if you are crazy enough to attempt such a task, and I can't imagine attempting a major without a lift. I got all my hoses from the local Goodyear hose shop and many parts from NAPA and Amazon.

    Major Service Parts

    512TR Major Service Kit (from dealer) $1495
    (includes belts, tensioner bearings, cam bearings, gaskets, fuel, oil and air filters)
    Intake manifold Gaskets (TRutlands) 77.44
    Exhaust gaskets (large) (TRutlands) 82.18
    O2 sensors, heater hose, small exhaust gaskets, crank sensors, constant torque clamps, brake kleen
    (NAPA) 707.51
    Air check valves (Rock Auto) 31.87
    Thermostats (Advance Auto) 28.65
    Water pump seal (East Coast Jaguar) 47.90
    Hoses and constant torque clamps (Goodyear) 219.19
    29 mm Shim Kit (NewCo Products) 399.00
    29 mmm Shim Kit (Z1 Enterprises) 102.56
    NGK Spark Plugs 100.74
    Redline Gear Oil 171.45
    10W-60 LiquiMoly Oil 95.74
    Evans Waterless Coolant 279.12
    RedTek Refrigerant 65.85
    LocTite 518 sealant 18.27
    Permatex Anti-Seize 4.99
    Hylomar Sealant 20.15
    Red Line assembly lube 10.84
    VHT wrinkle coat paint (red and black) 30.10
    LocTite 5.97
    KriKit Belt tension gauge 12.20
    Wire Clamp Kit 22.89
    SS Flat washers M6 13.14
    Nylon Metric Locknut assortment 14.89
    Acorn Nuts (SS) 23.98
    Permatex Assembly lube 5.99

    TOTAL $4,087.61

    Now, if you are not going to do the valves, or if you re-sell the unused shims, you can knock $500 off the total. If you can re-use the exhaust donuts, save another $150, etc.
     
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  3. flash32

    flash32 Formula 3

    Aug 22, 2008
    2,458
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    Dominick
    Basic tools and lift I see but shouldn't we count the engine crane .. not something everyone has ?

    Great detail btw .. amazing the real life cost .. I thought it would have be a little lower but things add up quickly

    Sent from my moto g(7) using Tapatalk
     
  4. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    I opted for a new Sanden (not a knock-off) AC compressor from Polar Bear along with a new high side fitting and R-134 service ports to make AC work so much easier $615.82
    I had Wizard Cooling make some custom aluminum radiators $2208.30
    And new SPAL cooling fans $264.00
    I like Hill Engineering and bought their tensioner bearings (Ricambi) $162.50
    And I replaced the Hill Engineering clutch release bearing (Ricambi) $430.20
    The CV boots looked shoddy, so they were changed (TRutlands) $292.36
    CV boot clamps $10.59
    CV Boot pliers $28.74
    Red Line CV Grease $15.99

    TOTAL $4028.50
     
  5. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    Oh, I'm not done yet. And yes, a crane is a necessity.
     
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  6. flash32

    flash32 Formula 3

    Aug 22, 2008
    2,458
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    Dominick
    I know you mentioned 7 months but if somebody was dedicated doing this every day including waiting for parts what would it take

    Sent from my moto g(7) using Tapatalk
     
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  8. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    And while the engine was out and sitting on the stand (you DO have an engine stand, don't you?), it seemed like a good idea to replace the connectors with gold terminals:
    100 Gold terminals (Mouser Electronics) $48.19
    Terminal extractor set $8.59
    Terminal Crimp Tool $23.99
    And it seemed like a good idea to clean up the battery compartment connections:
    Hydraulic Crimper (Harbor Freight) $64.19
    Battery Crimp-on Lugs $5.99
    Distribution blocks $30.98
    And the Cam Phase Sensor Connectors had to be replaced:
    Junior Power Timer Connectors (EFI) $72.34
    And the fuel pump seals needed changing:
    Fuel Pump Kit (Scuderia Rampante) $138.00 (estimate, I lost the invoice)

    TOTAL $392.27
     
  9. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    And Flash is correct. If you don't have a lift and an engine crane and a stand to hold the engine, better borrow them or don't attempt the service. Again, this assumes you have, or can borrow an AC Vacuum pump, AC Manifold and gauges, etc.

    And just some miscellaneous costs that I incurred:
    AC Coolant can tap $10.99
    Zero Pressure Radiator cap (Summit Racing) $15.98
    5/8" barb fitting (Lowes) $2.64
    Threaded rod (Lowes) $5.46

    TOTAL $35.07
     
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  10. JIMBO

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    So, the GRAND TOTAL of expenses for my DIY 512TR Major Service was $8,543.45.
    The enjoyment and pride in doing it yourself is priceless. Plus, you know it is done right.
    I did NOT replace the clutch ($2,400) and I had the tools to change the valve shims and set the cam timing from past adventures. I have a lift and engine stands and cranes and bead blast cabinets and TIG/MIG welders, so I was able to do a lot in-house, saving time and expense. Plus, I had the experience of doing 3 of these majors in the past.
    Oops, I forgot the ceramic coating on the exhaust $640.

    New Grand total $9,183.45

    In terms of time if you were dedicated to doing it every day, it is hard to say. When it's YOUR car, you see little things that a mechanic on the clock might ignore, but you will take the time to do it right. My car is set. I'm not touching the engine for another 40,000 miles except to change the oil. My 36,000 mile belts looked just the same as my 11,000 mile belts and my brand new belts. I only had to adjust a few valves and they were minimally out of spec. I have all new hoses and an upgraded electrical system. I double-checked and triple-checked everything and still had a few screw-ups that I fixed.
    When dealing with Italian cars, waiting for parts is a big pain. When I decided to change the CV joints it took 6 weeks to get the right parts. You always find stuff you did not think about as you go through the service. I opted for Constant Torque Clamps. Much better than the original, but also a $200 added expense. But now I don't worry. I chose silicone hose over rubber. Another $200. Hill Engineering tensioner bearings - $162.
    I did not have to change the radiators and fans or ceramic coat the exhaust system, but now it''s all more efficient. Worth the $3000? Probably (I live in Florida).

    In the end, it all depends on how much you want to drive and enjoy the car and how much peace of mind that your vehicle is better than new is worth. It is a lot of work. Honestly, hundreds of hours for someone like me. But it is fun, when someone asks, to look them in the eye and say "I did it myself".

     
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  11. JIMBO

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  13. JIMBO

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    PS: I'm NEVER doing this again. I figure I'll be in my 80's when it's time for the next major. If I'm still alive and driving, I'll pay my friend Dino Sanzogni to do the work.
     
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  14. PA32Pilot

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    Great job!!!
     
  15. KevZep

    KevZep Formula Junior

    Feb 17, 2020
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    Kevin Bennett
    I really enjoyed your other thread detailing the major service, and of course this one is a nice bonus giving costs and insight.

    Must be a good feeling getting all that work done!!

    I'm sure you wont waste any time getting out and enjoying your car!!
     
  16. greg328

    greg328 F1 Rookie

    Nov 17, 2003
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  17. xplodee

    xplodee Formula 3
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    Well done!
     
  18. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    Jim DeRespino
    I should give a special thanks to Ray Garbe at TRutlands, Daniel at Ricambi, Joe and Gretchen at Polar Bear Inc, John DiGiacoma at East Coast Jaguar, Dave Helms and Travis at Scuderia Rampante and Jim Wieczorek at Wizard cooling as well as super F-Chatters Tim Fulmer and Clyde Romero.
     
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  19. vincenzo

    vincenzo F1 Rookie

    Nov 2, 2003
    2,928
    In your 80’s!?!
    Presumably you are now in your 70’s.

    My hat’s off to you for that accomplishment in your 70’s!
     
  20. JIMBO

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    Not quite. I turned 66 last week.
     
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  21. Zeff

    Zeff Formula Junior

    Oct 8, 2018
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    Ryan
    I love the way you attack the major and all in.
     
  22. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    it's great to have it done.
     
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  23. Clyde Romero

    Clyde Romero Formula Junior

    Sep 6, 2019
    533
    Atlanta Georgia
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    Clarence Romero
    nice work Doc

    clyde

    ps just did my fuel pumps ugh
     
  24. Clyde Romero

    Clyde Romero Formula Junior

    Sep 6, 2019
    533
    Atlanta Georgia
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    Clarence Romero
    how are you liking the radiators?
    they should cool the car down quicker
    I love mine
     
  25. Clyde Romero

    Clyde Romero Formula Junior

    Sep 6, 2019
    533
    Atlanta Georgia
    Full Name:
    Clarence Romero
    you did it right Doc
    you will not regret the radiators living down south
    I know I haven't
    I stayed with the R-12 system and it cools down to 38 degrees when's its 98 outside
    as for the belts
    I change mine every 45k miles never by years
    but I drive my car like you do it doest sit like the majority of the owners
    if you drive the car the belts will go the distance
    as for your transaxle if your like me it will last
    will come visit soon after this virus goes away
    once again
    congrats on a job well done
     
  26. MOSS

    MOSS Formula 3
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    Apr 28, 2004
    1,497
    Nice job and if you are retired its the way to go. I am lucky to have probably one of the best techs in the United States close by and
    I can make a lot of money working while I let him do it for 10k and feel perfect about it. Better than perfect because I guarantee he can do
    it better than 99 % of do it your selfers. I am getting ready to stop doing frame off restos and enjoy my life. It is a must that you have this kind
    of Tech though. Also 99 percent of the owners here could not begin to take on this job, Lol
     
  27. ttforcefed

    ttforcefed F1 World Champ
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    Aug 22, 2002
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    what is the total hour count so far?
     
  28. JIMBO

    JIMBO Formula 3
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    Oct 31, 2003
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    Jim DeRespino
    Thanks, Clyde,
    The new radiators do cool quicker, but not as dramatically as yours probably because I used the Evans waterless coolant. They are worth the cost and the Wizard Cooling folks are great to deal with. Thanks for the referral.
    500+ miles now since the major and everything is functioning like new.
    I'm planning a few post-pandemic road trips myself, but for now staying near home.
    I agree 100% on the belts.
    So far the AC is spectacular - it gets too cold. Not a bad problem in Florida. I have a 3-M tint on the windshield that helps cut down on the heat (and all the UV rays) considerably.
    Jim
     

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