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Discussion Starter · #1 ·
Well, I had a large chunck of change from selling my house that I had set aside for my engine/transmission/turbo kit build. Turns out that my transmission plans have changed. I had initially planned on simply doing the standard mods that are common now like revised shift forks, Torsen diff, "Koated Kogbox", Tower Replacement, ect. through Terry Haines (HMS). I was looking to spend around $2,500 total, but after talking with Terry and picking his brain, we agreed that the trans still wouldn't be bullet proof and with the power I plan on making the abuse I plan on feeding through the driveline on the track that other plans had to be made. So, I have taken the plunge and opted for the Quaife gear set (synchromesh, not dog engagement) with the following gear ratios (FD = Final Drive):

1st: 2.643
2nd: 1.824
3rd: 1.4
4th: 1.130
5th: 0.962
FD: 4.467:1

For reference, the stock gear ratios are:

1st: 3.42
2nd: 2.14
3rd: 1.45
4th: 1.03
5th: 0.77
FD: 4.06:1

This thing is going to SCREAM out of the corners! Best part about the custom gears set is it comes with a choice of 5 final drive options ... I chose the one nearest 4.5 based on advice that I got from Leo Capaldi a few years back when I first began considering this project. My other FD options where: 3.824, 4.125, 4.467, 4.857, 5.308 ... the last two are just TOO low for a road racing car. I figured since I was going with the Quaife gear set, I might as well go with the Quaife Diff. So, I have a Torsen ready to drop in if anyone is interested: Torsen For Sale

When the project is complete, I will disclose all the details of the build along with pictures if Terry can get them while he is rebuilding and prices. As a point of reference, I just sent Terry a deposit of over $4K
 

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that's awesome! with a whole lot of paower and those short 4th and 5th gears this thing will be a monster on the top end, but it will top out pretty quick prolly...about what 130-140? maybe?
 

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Discussion Starter · #5 ·
After doing the calculations with I am leaning towards the tallest final drive option of 3.824.

FD Options = 3.824, 4.125, 4.467, 4.857, 5.308

The final drive combined with the gearing plays a HUGE role in top end speed. This will be a track car that sees occasional street use, but mainly a track car. The track that I will be running on has a VERY long front stretch, which in a stock Cougar, I was able to hit 118MPH before entering turn 1, so my final drive ratio selection will be critical.

The engine is a fully build race engine (Pauter rods, Diamond 9:1 pistons, ADC T3/T4 turbo, running 104 octane, ect.). I plan on a minimum of 400 FWHP. That being the case, the car will have plenty of power to come out of corners, so that rules out the 5.308 and 4.857 FD ratios. So, I guess top speed is my final decision.

Using this calculator and assuming a tire diameter of 24.97" (225/45 R17), and an RPM of 7,000 the top speed of each gear is listed below for each differing FD.

Final Drive 3.824:1 @ 7,000 RPM
1st: 51.47 MPH
2nd: 74.58 MPH
3rd: 97.16 MPH
4th: 120.38 MPH
5th: 141.41 MPH

Final Drive 4.125:1 @ 7,000 RPM
1st: 47.71 MPH
2nd: 69.13 MPH
3rd: 90.07 MPH
4th: 111.6 MPH
5th: 131.1 MPH

Final Drive 4.467:1 @ 7,000 RPM
1st: 44.06 MPH
2nd: 63.84 MPH
3rd: 83.18 MPH
4th: 103.05 MPH
5th: 121.05 MPH

For reference, stock tire is 215/50 R16 = 24.46"

Final Drive 4.06:1 @ 6,750 RPM
1st: 35.38 MPH
2nd: 56.55 MPH
3rd: 83.46 MPH
4th: 117.5 MPH
5th: 157.18 MPH (Drag Limited to 143 MPH)

Obviously, I loose A LOT of top end with the 4.467 FD, so even though I was thinking of going that route to be a beast coming out of corners, I think that it's WAY overkill considering the power I will be making. I definitely leaning toward the highest 3.824 FD.

Your thoughts???
 

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Discussion Starter · #6 ·
BTW, here is the track where I plan on running: Summit Point Raceway - Summit Point Circuit

The front stretch is 2900ft long ... that's almost a 1/2 mile of acceleration (have to leave room for braking into turn 1, which has a 35MPH approach speed. It's a double apex opening radius right hander)
 

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Discussion Starter · #8 ·
Bad new ... gear set can not be procured due to it only working with the I4 MTX ... the input shaft is too short for the V6 application :mad:
 

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With that amount of power I would agree that a 4.46 final drive might be a bit much. I know with the Euro B1 gearset and the 4.5 final drive, I have had the car up to 135mph and was at about 6200-6500RPM. The 4.5 final drive does make the car quite mean matched up with the 2.5L, but anything more then a standard 3.0L Hybrid with a 4.5 final drive would be too much. You would lose to much top end for your application, and I can tell you for street use I could almost get away with not using 1st gear, if I didn't like get pushed back into the seat so much.:biggrin: Hope that helps.
 

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Discussion Starter · #10 ·
OK, due to not being able to use the gear set in question, we have decided to beef up the stock set with a 3.82 FD. It will play out like so with 225/45 R17 tires:

To compare apples to apples, RPM is stock redline of 6,750

Stock 4.06 FD:

1st = 3.42:1 = 36.12 MPH @ 6,750 RPM
2nd = 2.14:1 = 57.73 MPH @ 6,750 RPM
3rd = 1.45:1 = 85.2 MPH @ 6,750 RPM
4th = 1.03:1 = 119.95 MPH @ 6,750 RPM
5th = 0.77:1 = 160.45 MPH @ 6,750 RPM (drag limited to 143 w/ 170hp 2.5L V6)

Not Stock 3.82 FD:

1st = 3.42:1 = 38.39 MPH @ 6,750 RPM
2nd = 2.14:1 = 61.36 MPH @ 6,750 RPM :cool: 0-60 without shifting to 3rd
3rd = 1.45:1 = 90.56 MPH @ 6,750 RPM :thumbsup:
4th = 1.03:1 = 127.49 MPH @ 6,750 RPM :thumbsup:
5th = 0.77:1 = 170.54 MPH @ 6,750 RPM
(don't plan on finding out the drag limit w/ 400+hp 3.0L Turbo V6)

Intended RPM setup:

1st = 3.42:1 = 41.24 MPH @ 7,250 RPM
2nd = 2.14:1 = 65.9 MPH @ 7,250 RPM
3rd = 1.45:1 = 97.27 MPH @ 7,250 RPM :thumbsup:
4th = 1.03:1 = 136.93 MPH @ 7,250 RPM

5th = 0.77:1 = 183.17 MPH @ 7,250 RPM :evil:
 

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terry is the straight poo he is awesome i am so happy with my tranny i got from him..

terry is the tranny god

i didn't have that amount of money to put into the tranny so i opted for the standard....koated kog, quaife, slick shift forks, and also he rebuilt the tranny also
 

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Discussion Starter · #12 ·
Terry is getting the transmission tonight and the Torsen on Tuesday night ... hope to have it back sometime in about 2-3 weeks.

1) Hot tank the case and then have it "show prepped" with candy apple red :naughty:
2) Use the later (current) "solid pinion" style output shaft with matching ring gear. Has a FDR of 3.82 vs. 3.84
3) ALL 'shrunk/pressed on' fixed gears will be machined on both gear & shaft and 'keyed' to shafts.
4) Free running gears will have 'dog ring' part of gear also keyed to main gear to avoid "spinning" at high HP on the shafts.
5) Double synchro 3rd gear if it only has a single synchro
6) Coat all gears/blocker rings, aka "Koated Kogbox"
7) Fit revised forks, aka "Slick Shift"
8) Fit Focus Shift Tower
9) Fit new throw-out bearing/slave cylinder
 

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why the torsen over the quaife. price vs performance?
 

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Discussion Starter · #14 ·
Originally posted by: fordrule
why the torsen over the quaife. price vs performance?
1) I already had it
2) I bought vs. the Quaife because of the higher torque bias 3:1 vs. 2:1
 

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Discussion Starter · #16 ·

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Discussion Starter · #18 ·
Found out from Terry today that the transmission in getting some machine shop work done so it has been cracked open and assessed. The gear teeth on the diff where starting to shred themselves ... damn glad I sent it to him now! To save a few bucks, I initially thought about trying to fit the Torsen and shift forks myself ... I'm SO glad I decide to take the plunge and spend the extra money. It's going to pay HUGE dividends on the track ;)
 

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You are 100% correct about this. Once you get past the fact of droping that kind of cash, the fact that you just drop it off then pick it up FINISHED is huge. Terry does such a great job too, he leaves no stone unturned and doesn't BS with you, he'll let you know exactly what you do and don't need and why! I was so please with my trans when I picked it up and I would never attempt trans work myself, beyond clutch and flywheel replacement.
 
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