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Forums › Tuning, Modification & Legal › Project Cars › Project sleeper


 
 

Project sleeper
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Edward
PostPosted: Wed Nov 22, 2017 7:23 am Up
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Joined: Feb 08, 2010
Posts: 6934
Trade Rating: +5
Location: In the garage


So I now have one 307cc 180 gearbox (code 20DM43) and another Picasso 1.8 gearbox (20DM71), as well as the original 20DM17 from the 206 GTI and 20DM71 from the first Picasso.

The 307 CC 180 gearbox comes with a 17x73 = 4.29 final drive which might be a good compromise in terms of ratio. I will be fitting the shorter 4.76 from the Picasso though.

My plan is to fit the 307cc 180 ratios (inc tall first gear) with the short 4.76 FD and the 5th gear from the Picasso as 65mph meant 4k rpm. The taller 5th gear should mean 4k rpm equals 78mph. Perfect for motorways....not that it will be used on motorways.

Lots of spares NOW!
 


 


 

2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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Edward
PostPosted: Wed Nov 22, 2017 7:30 am Up
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Posts: 6934
Trade Rating: +5
Location: In the garage


And ive also found a few small differences between these gearboxes which vary from bearing thicknesses and diameters to changes in the gearbox casings . I will take pictures later.
2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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Edward
PostPosted: Sat Nov 25, 2017 10:50 am Up
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Joined: Feb 08, 2010
Posts: 6934
Trade Rating: +5
Location: In the garage


As the car will be going back together soon I've started buying some little bits.

£6.19 for a new clutch release bearing from GSF.

 

2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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Edward
PostPosted: Fri Dec 01, 2017 5:28 pm Up
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Posts: 6934
Trade Rating: +5
Location: In the garage


More from GSF car parts.

£16.64 for an FTE clutch slave cylinder. Same brand as the OE part.

 

2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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Edward
PostPosted: Sun Dec 10, 2017 9:25 am Up
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Joined: Feb 08, 2010
Posts: 6934
Trade Rating: +5
Location: In the garage


Both the GTI 138 AND 307CC 180 gearbox housing went for soda blasting and they both cleaned up pretty well. The 138 housing which I will be using had been cleaned up to remove any soda has started to change colour already. It might be the white spirit that I used to clean it out with.

 


 


I've also ordered new driveshaft seals and reverse switch with the JPT connection rather than the standard peugeot plug. I'm trying to get rid of standard peugeot plugs as id rather use the more widely available JPT plugs.

2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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Edward
PostPosted: Fri Dec 15, 2017 5:11 pm Up
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Joined: Feb 08, 2010
Posts: 6934
Trade Rating: +5
Location: In the garage


Noticed another difference earlier. I just happened to put the original 138 GTI diff next to 2 of the other diffs I have. Looks like the crownwheel attached to the opposite face on the diff flange...

 

2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio. 2006 VW Jetta 2.0 TDi Sport. 2009 Audi A3 convertible 1.8T S Line
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