CLUTCH AND TRANSMISSION

My clutch and driveline gave me grief for over 2 years! In this time I went through 2 stock clutches and two heavy duty clutches! Putting the torque of the new turbo motor through the stock 200mm clutch just wasn't going to work so I had to find a solution! Thanks to the guys from www.4g61t.com - I found an upgrade that sounded like it would work!

So what did it involve? Well the guys in the states are lucky enough to have the 4g61t engine sold locally in what they term a Colt GT Turbo. (See below for a pic) It is basically the same as my car but is only sold in the 3 door variant. So what transmission do they use? Well - the FWD versions use a KM210 gearbox (with a flat 215mm flywheel) and the 4wd versions use a F5m33 gearbox (with a recessed 225mm flywheel) - The km210 can fit a 225mm flywheel though - It all gets pretty confusing doesn't it!

Well to cut things short - the 225mm flywheel uses the same clutch as a GVR4 - EVO and CC Lancer GSR and can fit in a KM210 so that is what I wanted! But where do I get a km210 from? Whilst scouring the boards I discovered that someone had found a km210 in a early 90's 2.4L Hyundai Sonata in the states! So I started looking into it but couldn't find any - then one day whilst snooping around a Hyundai wrecker I came across one!

 

 

 

The one on the left is the stock Oz delivered CB Lancer GSR Gearbox - F5M22

The one on the right is the KM210 from the Hyundai Sonata.

It does not look like there is much of a difference but the KM210 lets me run the 225mm flywheel and clutch! AND the gear ratios are SO much better (heaps taller and suited to the torque of the turbo engine)

 

 

 

 

So I picked it up and took it home and prepared to put it in... BUT I had not known about the flywheel at this stage! I had a GVR4 flywheel but when that was put in with the new starter mounting plate - it wouldn't line up :( So I had to source a FWD Turbo DSM Flywheel from the states as it had a larger overall diameter (about 5mm) to allow the starter to actually reach the ring gear and crank the motor!

The top left is the FWD DSM Flywheel (thanks to jmauld from 4g61t.com for sending it to me!) The one to the right of it is the stock VR4 flywheel that is too small in overall diameter for the km210 bell housing. Below that is the stock CB 1.6 n/a 4g61 GSR flywheel (215mm and non stepped) and to the left of that is a stock 4g61t 4WD Mirage/Colt GT flwheel (exactly the same size as the GVR4 one)

 

 

 

 

Watch out for the tranny mount too - if you cant find the raised KM210 mounts - I just used my stock flat engine mount and cut the mounting point on the actual transmission flat (using a hacksaw and file) Take a look at this pic to see what I mean.

Another problem I encountered were the shifter cables. I found that when I fitted my KM210 - it was slightly too short to properly shift forwards and backwards on the transmission (ie. left to right on the actual gear lever)

The solution was to get a set of adjustable cables from a standard model lancer of the same generation as mine. I picked up a set for $44aud from the wrecker/junkyard and spent a few hours putting them in (yes it is a pain to get them out!) once they were adjusted to give a little more length it works fine!

 

 

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