1.6 Gearbox Choices

[cocopops2001 2]

Hello All,

 

I have recently purchased a 1.6 CTi and while all is more or less fine there is a little bit of crunch when changing from 3rd to 4th gear (and sometimes from 2nd to 3rd if Im a bit rough with it).

 

I have been working away for a bit so not had much opportunity to route around but I'm hoping its something simple like linkages are worn.

 

While on motorway the engine is a little revvy due to the ratios, I have noticed a couple of people on her mention the same thing.

 

Is it worth changing the box for a Saxo one? (Also saw that on here :-) ). I would like to keep the off the mark quick acceleration but would like the final drive to be a little quieter when on faster roads. The car is going to be a more or less everyday runabout though at the moment its only used for weekends.

 

Is it worth doing this change and is it a straight swap of boxes or will I have to modify clutch etc?

 

Any info on this would be great. Thanks.

[Anthony 1,003]

Saxo and 106's use an MA series bearbox, whereas a 205 GTi is a BE series gearbox.

 

Even if you could swap it (easily) then I wouldn't, as MA boxes are made from chocolate frankly.

[cocopops2001 2]

ok. so what would you recommend if it turns out that the gearbox is knackered? try and source another 205 box/get mine refurbished? If I was changing the box I would ideally like one that is from a newer car.

 

would putting in a 1.9 box solve the high revs on the motorway issue or do you think I should just live with it?

 

is there anywhere I can see the ratio's for the two boxes?

[Anthony 1,003]

Personally, putting a much longer gearbox on will just make a comparitively gutless but rev-happy engine like a 1.6 GTi feel underwhelming and dull.

 

It's obviously a subjective thing, but I've never found the short 5th to be an issue on the motorway and previously I've been doing over 20k a year and driven across Europe like that - having an interior/sound deadening and a standard exhaust helps massively though it has to be said, as it's nasty in a stripped out car with a loud, boomy exhaust.

 

1.6 and 1.9 GTi gearboxes have similar ratios - the main difference is the final drive (4.06 vs 3.69) which makes the 1.9 gearbox approximately 10% longer in each gear. Might not sound like much, but believe me, it makes a huge difference going from one to the other.

 

Personally, I'd just get another 1.6 gearbox, but if you really must change it to something more modern and want a taller gear for cruising, then a Xsara VTS gearbox would probably be a good choice. The ratios aren't as closely stacked as the GTi gearboxes, so you get a comparitively short 1/2/3 and a longer 4/5

 

There's a very good gear ratio spreadsheet/calculator out there somewhere - I'll try and find it...

[Anthony 1,003]

Found the link for you:

 

BE Gearbox Ratios Spreadsheet

[cocopops2001 2]

Thanks.

 

The thing about sound deadening may be a bit of a non issue as wind noise becomes almost unbearable at around 80mph as it is the soft top. I don't plan on doing much mods to the car as I have bought it as just a bit of fun and dont have a space to do the kind of work needed to prepare a track/road race type car.

 

I was really just wanting some info what to look for if indeed the gearbox does go.

 

Bit of a tangent here but do you know of anyone who has fitted a turbo to the 1.6 engine or am I heading down a road that shouldn't really be travelled?

[Anthony 1,003]

There's an good project thread by Tom Fenton where he's turbocharged a 1.6 engine with excellent results here that's well worth reading

[welshpug 1,661]

yes, Tom Fenton, have a look at the project threads section.