Picking Up the Pieces

Originally posted: 04-12-2011

Time to pickup the pieces and get back on the horse!

The transfer case housing cracked and twisted.  When it did that, the transmission shaft twisted and broke off inside the transfer case.  So the transmission is done.  Although the primary housing on the transfer case is broken, it appears that the front LSD and ring&pinion are completely unharmed.  So I will be saving this T-case and sending it out to be built up as an extra to keep around.

Time to start planning!

I picked up a used low mileage (38k) 5-speed transmission and ACD transfer case out of the 2005 Evo.  The 5-speed is the choice for racers, as it has a higher torque capacity than the 6-speed.  The 6-speed transmission was designed with a 260-290ft.lbs fatigue limit.  It also nearly no ability to change gearing or build up.  The 5-speed on the other had, has a factory fatigue limit of nearly 100ft.lbs more than the 6-speed.  A transmission generally has an over-builf of about 50%.  So prior to the build up and shot peening TRE will be doing, it has a limit of roughly 550ft.lbs.
The transmission and transfer case are off to TRE to be built up.  The transmission will be getting a beef-up and a 4.11 final drive gear that will allow me 71mph at 8000rpm on the 23.8" Goodyears.  The transfer case is being converted to a non-ACD setup.  The factory ACD uses a fluid pump to change T-case pressure to vary the lock of the front differential.  By removing this, it should make the cars on and off throttle handling a little more predictable and shave about 20lbs of weight off the front left corner.

Hopefully I'll have them back and in the car in the next couple weeks.  Thanks to a friend, Terence Cox, I was able to score a 5-speed shifter/cables and the needed mount to do the conversion.  One added item, to resist future failure will be an upgraded torque mount.  Along with taking the rest of the ProSolo's out of my season, I'm hoping these will promote a longer life for the drive-train.





 

 Thinks to do once the car is back together and driving:

1) Re-Dyno Tune with better fuel.
2) Roll/Flare fenders for more tire clearance, allowing the car to be lowered more.
3) Remove full dashboard and remount gauges to crash bar.
4) Remove tar on vehicle floor, and sound deadening behind dashboard.
5) Remove headlights and A/C to weight off the front end.


I'm hoping to take the 440lbs I need to get the car down to just 20lbs above minimum weight.


Hoping to be back together and pulling weight off within two weeks!  Crossing my fingers!

-Mike