71 replies to this topic

[jack be nimble]

It must be a turbo gearbox.
I have a na fwd 6bolt flywheel if you need it measured.

[croket]

Whats the code on the gearbox ? , i think thats the key info needed ... Km210 is in the ggsr and is baby box i know there is also another fwd box that suits vr4 flywheel km230 i think.

[speedy]

It must be a turbo gearbox.
I have a na fwd 6bolt flywheel if you need it measured.

[speedy]

Hi thanks that would be good think this vr4 one is to small

[jack be nimble]

Mine should be the same as yours. But if you have a turbo gearbox, the usa sites say they are heaps better than a na box. So you are worth getting the correct flywheel rather than changing the box.
Either way, it looks like its coming back out

[speedy]

ok think i have a jap spec import cb gsr so gearbox dont fit 4g61 or 63 the starter mount on the gearbox is all wrong so i will need to sort out getting another box i am running a VR4 motor am after a two wheel drive gearbox to suit any help would be good thanks 

[jack be nimble]

If you put a na box behind the turbo engine you will break it. I think you have a turbo fwd box that will handle the grunt.

Edited by jack of all, 17 June 2014 - 10:39 PM.

[speedy]

Gearbox numbers kbooapw fq2295

[xjokux]

The stock gearbox should fit though can't guarantee how long it'll last. I know some who's gone through 3+ boxes and others just one.

 

I've got a vr4 gearbox can take alot of abuse and withstand the torque. Weld it up to get power just to the front, lighten flywheel and exedy Hd clutch. 

 

No problems yet. Aside its bitch to get the box in cause its almost twice the size and weight of stock.

[jack be nimble]

Gearbox numbers kbooapw fq2295

Oops, you said that before.
Anyone know what this box is?

[jack be nimble]

This may help:
http://www.members.o...nzo/tranny.html

[jack be nimble]

CLUTCH AND TRANSMISSIONMy 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 - F5M22The 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!

[Big M]

Don't waste your time with the CB 1.6L F5M22 gearbox and clutch setup. The turbo motor has too much horse power and torque for this setup and all you will do is fry your clutch and snap your gearbox.

 

The KM210 is a better option with the 225mm clutch with a Fidanza flywheel plus a HD or 6 puck clutch to suit your driving style. The FWD torque steer makes driving interesting, remember to always look left when you are in a hurry !!!! Change the pivot ball in the gearbox, check the select fork that it is straight with no cracks. When the gearbox is bolted up, make sure the fork is in the correct position if not pack the back of the pivot ball with a washer. This will give you the correct movement on the clutch so you will not over/undre extend the clutch set up. Use the mounting plate from this FWD 2L will bolt up but you need to make one of the starter hole bigger (can't remember which one) line it up against the gearbox to check.

 

Use a complete gear lever setup (every thing under the gear shifter boot) from a CC lancer and this will make the complete setup a short shift due to the lever mechanism, don't forget to put new bushes as they would be worn out. Use the adjuster on the shifter cable to get the gear selection correct. Change to brass inserts (Not sure if Meek still sells them) on the gear shift cable where it attaches to the gear box.

 

Choose the correct setup for the horse power you are chasing and take you time so you won't have to redo...........

[speedy]

well think i have km210 already so think i just need starter to suit that gearbox ?? hyundai box yeh ???

[jack be nimble]

There is a heap of info around. Try here:
http://www.4gtuner.c...rbox-for-4g61t/

Without pulling the box first there is one thing to try.
Count the teeth on the flywheel. 106 will be awd wheel, 110 is fwd. I dont know what the turbo fwd wheel has. But maybe I have the same one here on my sonata engine. it seems the sonata had a km210 size box but others only talk about the early pre91ish boxes. Mine is the 2.0 93-99 engine.

[croket]

i think a galant fwd starter would work

Edited by croket, 18 June 2014 - 11:16 AM.

[jack be nimble]

I think all the starters are the same

[croket]

they seem to bolt up the same but im not 100% if they all fit the same. If your using the km210 box with a vr4 engine then get a galant gsr flywheel and clutch it will work with vr4 engine and that box with the galant starter.

Jayrome has a nice ggsr clutch he would sell , its a 4puck and will hold good power

[jack be nimble]

I reckon my sonata flywheel is the right one too.

[Marc]

If you put a na box behind the turbo engine you will break it. I think you have a turbo fwd box that will handle the grunt.

 

Wrong answer, the guys who was first to reply to the OP in the this.. in 2011 had a 61 GSR box on his vr4 conversion, i drove that car as my daily for about 12-18 months when he owned it, relentlessly giving it arseholes. These days, that very gearbox has been in my VR4 converted excel with slightly more power again, driven relentlessly.

The saving grace is due to two factors, small clutch (200mm), and the fact the ratios are that short that you either A, fry tyres, or B, fry the girly man 200mm clutch.

Results speak for themselves, by the way, that gearbox, would have approx 270,000km on it, another 30,000 i'll pull it out and mount it on the wall, because really it shouldn't last that long, especially with taking off like this in 2nd gear.

 

 

Yes sonata flywheel works, used one in my CC lancer coupe with CC GLXi gearboxes, note i said gearboxeS, not gearbox, that gearbox, has awesome ratios, but the gearset is weak as piss with 3rd cog made from glass, as that was the one that used to go bang all the time.

Edited by Marc, 22 June 2014 - 11:12 AM.