10 replies to this topic

[VIN18M]

Ok guys, I've got a turbocharged factory 4g93t in my satria GTi, it has the stock gearbox and a heavy duty clutch that I think is on it's way out after 5 good years.
My issue is that I'll be putting in a vr4 rs engine soon but was hoping I could upgrade to a clutch that will still be compatible with the new engine and associated flywheel when the time comes for it to go in..
Is there any way of getting around this?

[DOUGMO]

evo 1-3, vr4 and 1.8 gsr all run the same clutch, so just get one to suit you goal power

[jack be nimble]

not sure of what you are running regards gearboxes, but the fwd gearbox needs a fwd flywheel to suit and a awd gearbox needs a awd flywheel (and starter?).

as Dougmo said, all the clutches will fit to either awd or fwd flywheel.

just a fyi
i am thinking that the vr4 rs engine will have a awd flywheel, and it wont fit in your fwd gearbox. i hope you already know this and have planned accordingly

[EVL20T]

Upgrade to an AWD box, the OEM fwd wont last too long with the power and torque of the 2ltre

[Evo-00x]

You wont be able to use an AWD EVO/GSR/VR4 clutch as it sounds like you've still got a FWD gearbox and FWD flywheel.
I presume at the moment you've just put your OEM 4G93P DOHC FWD flywheel on the 4G93T GSR engine and that is an easy and OK thing to do for what you have now in FWD setup.
But as soon as you change to a 4G63T engine, you're going to have some dramas sourcing a 4G63 6-bolt or even 7-bolt FWD flywheel to suit a FWD 1.8 Proton/Lancer GLXi gearbox.

Your FWD gearbox bellhousing hole size is 275mm in diameter, therefore ensure that whatever 6 bolt FWD flywheel you get, its size will measure slightly smaller diameter than this (including the ring gear teeth).
A normal 4G93 1.8 Proton GTi/Lancer GLXi FWD flywheel measures approx 268mm in diameter including ring gear and uses a 215mm diameter clutch disc.
You may have to source a FWD flywheel from a 6-bolt 4G63 Hyundai Sonata or Ive been told even a Mitsubishi Cordia turbo? Im not too sure of the exact specifics, as most people I know of just modify the AWD EVO/VR4 flywheel to suit.
What they do is have the raised stepped sections of the VR4/EVO AWD flywheels machined (and balanced) completely flat on the side that the pressure plate bolts onto. This will make it fit inside the FWD gearbox no problem.
The only downside is that because it is now a flat FWD flywheel, you can only use a 215mm diameter 4G93 FWD GTi/Lancer GLXi h/duty clutch kit. So if you like the clutch kit one you had before, just buy another one exactly like it.
Ive known several people to do exactly this thing for this type of conversion, therefore its probably your easiest and perhaps cheapest option overall.
You can still use the existing VR4/EVO starter motor too as you havent effected the ring gear teeth on the flywheel in any way

Whatever you do, DO NOT go shopping for a Mitsubishi Eclipse 4G63T FWD flywheel as they are 285mm in diameter including ring gear and physically cannot fit inside our Lancer FWD/AWD gearboxes.
The FWD Eclipses use a larger bellhousing transmission similar to our UF Nimbus does.
FYI, they run a 230mm diameter clutch disc.

The other alternative for your 4G63T conversion is to convert an AWD gearbox to FWD. But the cost in going this route is quite expensive because it involves a lot more work and parts.
To do this you will need an AWD gearbox for starters... preferably an EVO box with LSD = $$$$
Then you will need to buy a 2WD locking spline and fit it inside the back casing of the AWD gearbox... but it will make the AWD's gearbox centre diff spider gears a weak link that has often easily broken in many FWD converted 4G63T's.
Therefore you're better off forgetting about the 2WD locking spline, and instead open up the AWD gearbox and have the centre diff pinions welded in place. It will be much stronger and lock the AWD box to 2WD cheaper!
Then you can either keep the ouput shaft for the transfer case and viscous coupling in the box to hold the shaft in place, or you can remove the viscous coupling and shaft altogether and then fill in the hole where the transfer case output shaft once exited through the bellhousing with a welsh plug.
BUT, even now that you have an AWD gearbox box converted to FWD, you still cant fit the AWD box without an AWD K-frame and AWD crossmember from a GSR or EVO!!!.
This is definitely not the most cost effective way to go unless you have the parts available to you cheap.

[jack be nimble]

i have a 6 bolt fwd flywheel (and starter) if you want to swap for the 6 bolt awd setup. i can measure it if you interested. its on a hyundai sonata engine

or i know of a front gsr x member in sydney if you going that way.

Edited by jack of all, 13 December 2011 - 09:39 PM.

[VIN18M]

Thanks for all of the help guys, I didnt expect such detailed responses!

At this stage I'll be keeping the FWD gearbox so will maintain the same flywheel/clutch combo and go for the Sonata option for a flywheel later on as EVO00X mentioned...if the FWD box goes eventually then I'll look at doing the 4WD/FWD gearbox conversion.

So I guess I'll be going to another heavy duty clutch kit the same as what I already have in there...

Thanks again for your help guys!

[3zercrowd]

Here is a pic of the stock GTI clutch and flywheel that I had for sale a while ago. (still for sale lol)
No step as you can see in the flywheel as previously discussed.

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[jack be nimble]

Here is a pic of the stock GTI clutch and flywheel that I had for sale a while ago. (still for sale lol)
No step as you can see in the flywheel as previously discussed.

a 7 bolt gti wheel wont fit on a 6 bolt vr4 engine.
it wont even fit on a 7 bolt 4g63 as the dowel is positioned at the wrong spot. (could always grind it off)

[3zercrowd]

a 7 bolt gti wheel wont fit on a 6 bolt vr4 engine.
it wont even fit on a 7 bolt 4g63 as the dowel is positioned at the wrong spot. (could always grind it off)

Although it’s obvious that 6 and 7 bolts wont bolt up in any language, the pic is there for future reference since no one has posted any pics yet.
Maybe if we had a lot of side by side comparisons it may help visualise for the masses?

[Evo-00x]

oh you guys want pics???
Pic descriptions explain it all
Would be good if this can be stickied in the Misc Technical section under 'FWD turbo flywheel/clutch Conversion' or something...

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