Which Gearbox? 406 Sri Turbo Conversion

[Spesh 31 1 Cars]

So I've searched this to death but cannot make my mind up.

 

I've just aquired a running 406 sri turbo with the intentions of driving it for a bit while I strip the 205 down with the intention of transplanting the engine over to the 205 in the near future. My 205 is a 1.6 so I know I need to change the hubs so I can fit the larger shafts but I'm struggling to make my mind up on the gearbox.

 

I don't initially intend to 'tune' the engine outside upping the boost a little.

 

Options -

Keep the 1.6 box - I think it may be a bit short for the engine

Get a 1.9 box (or possibly a xsara vts box) - seems like a more likely match

Keep the ML (or is it ME?) box - may require a cut in the subframe for the diff (some say it does, some not) and will need the 406 shafts shortening to fit. Unsure if the outers would fit 1.9 hubs though

 

 

I'm thinking the 406 box may be a bit long? I've no experience of it yet as I've yet to collect the car.

Also I'll need to get a flywheel/clutch if I use a BE type box.

 

Anything else I should know?

 

 

Also are there any other parts from the 406 I can use if they are in good nick? Hubs would be ideal but I don't think they'd work - camber issues?

Edited December 27, 2015 by Spesh

[Henry Yorke 269 3 Cars]

I have a similar engine in my CTI and this had a box which was very similar to the 1.6 box. At 4000 rpm in 5th, I was at 70 mph, but that meant cruising was on peak boost and a bit jerky and annoying. I swapped to an Mi16 box with a 1.9 final drive, which gave me 1.9 ratios for first, second and third and a longer fourth and fifth. I now am at 70mph in fifth but my revs are 3200 and it is much nicer and the torque pulls it through.

 

However, it depends if it is a weekend toy or a daily. A 1.6 puts a lot of smiles on your face if you like changing gear quickly.

[Spesh 31 1 Cars]

Its going to be a weekend toy really but I think the 1.6 gearing will do my head in. It does a bit now with the 1.6 in really.

[dcc 855]

Fitted a1.9 xud diesel box to my friends car, 200bhp 8v turbo, he wanted long 5th for cruising. It does 70 at something silly like 2300rpm iirc, but it is bloody rapid through 1,2 and 3rd

[pugdamo 111 2 Cars]

A friend of mine also put a 306 1.9 d turbo box in and I thought the ratios would be to long but it was actually really well suited,top speed was way over the top though but it pulled like a train through the gears.

[Tom Fenton 1,542]

The diesel boxes give relaxed motorway revs, but there is a huge trade off and that's the gap between 2nd and 3rd gear. Paul Higgs 250bhp 8v turbo had enough grunt to get away with it but even so I personally found it quite annoying.

[Spesh 31 1 Cars]

yup I dont think a Derv box would be a good solution for me.

 

 

Does anyone have experience of keeping the sri box?

[wicked 103 3 Cars]

Keep in mind that the (stock) sri turbo engine is not a rev happy engine like the 1.6, so you don't want the box to be really short. That's anoying as well...

I have the 306 1.9 td box on mine (with 220bhp) and really like the long gears. 1st gear is a bit short, but I learned to live with it...

[Spesh 31 1 Cars]

If read that a few times, seems that even tuned a bit they don't do much beyond 6k hence why I'm having thoughts on keeping the stock box although I'm struggling to find reliable info on the ratios

[Miles 331 1 Cars]

even the 1.9 box is short on these as said above it's more like driving a Derv with the midrange torque and not allot else so a HDI box is suited to the engine. If it was a TT version then it's different again as these are allot more rev friendly.

Edited December 28, 2015 by Miles

[pugdamo 111 2 Cars]

I had the standard 1.9 box in my 309 when I did the 2.0 turbo conversion and as miles said I found it quite short in that,it wasn't bad but 2nd 3Rd and 4th didn't take long to go through, I never really found my mates diesel box a problem, it was easier to keep it boosting because of the longer gearing,we had our cars at different times though so I'm not sure what they were like side by side.

[Spesh 31 1 Cars]

Well I picked the car up tonight and I'm now leaning more to keeping the stock box if I can. It'll be reduced by around 8% (as far as I can work out) based on the rolling radius reduction going from the stock 406 tyres to the 195/50/15's I've on the 205 so I think it should work out about right.

Driving home tonight it was sat at 3k @70mph (gps) so will be 3250 give or take.

 

Does anyone know the actual ratios in the 406 box? google is failing me.

[dcc 855]

How did the wife take it?

[dcc 855]

The only info on a box I have found which comes somewhat close to yours is this

 

Xantia 2.0 SX 3.46 1.36 1.07 0.80 0.76 4.06

 

Send me your vin in a private message and I'll tell you better

[Spesh 31 1 Cars]

How did the wife take it?

 

She asked if I know whos car that is out in the lane.... I just made her a cuppa and dodged it, I'll tell her when she's pissed or something haha

 

The only info on a box I have found which comes somewhat close to yours is this

 

Xantia 2.0 SX 3.46 1.36 1.07 0.80 0.76 4.06

 

Send me your vin in a private message and I'll tell you better

 

I'll go find it in a bit, its not on the green slip and its like a swimming pool out in the lane right now

[Spesh 31 1 Cars]

Forgot about the vin number dcc, will do it tomorrow if its not peeing down.

 

 

Another question - If I keep the box out of the 406 how easy is it to put a hydralic pedal in (or convert the box to cable?)

 

Also looks like its cable change but that shouldnt be to difficult.

 

 

Edit - if those ratios turn out right that might just work out ok DCC (aside from the rubbish 1st gear). Would be 3200 @ 70mph

 

Should have enough torque to pull off the gap to 2nd I'd hope

 

 

all @ 6k with 195/50/15

 

1st - 29mph (lol)

2nd - 73mph

3rd - 93mph

4th - 124mph

5th - 131mph

Edited December 31, 2015 by Spesh

[welshpug 1,661]

the hydraulic clutch is straightforward enough, usually use a 206 master as its an easy 2 bolt flange and fairly compact, fits the later d9 406 and all the c5 slaves, I dont recall if the turbo box had the same clutch mechanism as the v6?

[Spesh 31 1 Cars]

Well after chatting with DCC at some ungodly hour last night I'm leaning towards a 1.8na diesel box. It looks to be the same ratio's as my 1.6 box but with a longer final.

 

If I changed 1st and 2nd from a 1.9gti box into it would be near spot on with changes keeping the engine in peak boost area.

 

This plan is massively evolving at the moment still

[Slo 283 1 Cars]

Following this with great interest as ive got the xu10j2te in my cti but from a very rare phase 1 605 and have just got a 1.8d box to try out but not before ive stripped it to inspect the important bits.