What improvements can be made to my gearbox???

[germantoy]

wondering what can be done to keep me from blowing the gear box up again. I have damaged 3 boxes now and am getting sick of it.

The box that was most recently damaged was out of a RS2 with the wide hard first gear.

Does anyone make a built first/main shaft for the 01e /cbd transmission?

[prosty]

What has happened , what car and what power are you making?

The S4 Biturbo tranny is good / better than an RS2 box

[Jamo]

You want an EDU or DSY box out of an S4.

What kind of spec do you have to be damaging the box? Do you have a lightened flywheel?

[germantoy]

im making 438whp

the b5 s4 boxes here are well really prone to blowing synchros out of them when using them as i would be (drag racing/fast shifts)

Jamo yes i have a lightened flywheel, basically its common here for people to Gaul (score) the first gear, basically chips the gear.

[Jamo]

That power is nothing and the box should be fine, the downside of using a lightened flywheel is the box takes up more stress.

Thats the function of the dual mass too counter balance harmonics sent down the drive train.

I'd recommened looking for an EDU box.

[prosty]

I agree with Jamo, however the dual mass flywheel cannot take the punishment of 500hp crank in my experience. I would have gone with a sm flywheel but not a lightened one.

The synchros are bad in all Audi 6-speed trannies in my experience, but you have to have the right oil, and if you shift correctly you can shift really fast without hurting the tranny, I'll make a movie later this summer and show you what I mean..

I'm doing the same amount of power like you, and I've never broken a tranny like THAT. Only 2 rear diffs and a few synchros , do you tighten the driveline before taking off? Try that, and what kind of clutch are you using? Springed sinter clutch is preferable with that power, so you don't stress the tranny too much.

There are ppl here in Scandinavia with 500+ whp that uses 6-speed trannies and they don't have the same problem that you're having. So start with getting a fresh DSY or EDU box. Change the oil to redline light shockproof. and throw away any possible short shift kits. And watch my tutorial later this summer

NEVER use a shortshifter with these boxes, you'll destroy the synchros in a few months.

[germantoy]

i come out of the hole hard 4500+ rpm launch and having a s6 avant shes no lightweight .
I have a sachs race clutch non sprung hub, ya prosty I HATE short shifters had one ruin syncros in my vw tranny so i swore off them for life.

Prosty what do you mean by this;" do you tighten the driveline before taking off?"

A few people here swear off Redline Shock proof because the shockproof additive clogs the "rifle holes" this was told to me by Stasis Engineering in California they are one of the few companies that rebuild these and upgrade the main shaft and 2nd gears by cryo treating and micropolishing them.

Id go back to dual mass but that thing is HEAVY and HUGE and i rev the car to 8000rpm +.

IM just tired of blowing them up

[v8 coupe]

Try a TDi box, they are tough from my research and might even have stronger bearings. the diesel engines have more torque at lower gears so they are designed for large torque loads. Just my 2 cents

[Jamo]

i come out of the hole hard 4500+ rpm launch and having a s6 avant shes no lightweight .
I have a sachs race clutch non sprung hub, ya prosty I HATE short shifters had one ruin syncros in my vw tranny so i swore off them for life.

Prosty what do you mean by this;" do you tighten the driveline before taking off?"

A few people here swear off Redline Shock proof because the shockproof additive clogs the "rifle holes" this was told to me by Stasis Engineering in California they are one of the few companies that rebuild these and upgrade the main shaft and 2nd gears by cryo treating and micropolishing them.

Id go back to dual mass but that thing is HEAVY and HUGE and i rev the car to 8000rpm +.

IM just tired of blowing them up

An OEM 7A or 3B flywheel will do IMO not a fan of lightened flywheels.

Regarding TDI boxes the ratios are different to petrol you'd really have to be careful and make sure the ratios match or are very close.

[germantoy]

Ya that means new matching ratio rear diff thats out. I think i may just pony up buy a new mainshaft and cryo treat it.

[germantoy]

An OEM 7A or 3B flywheel will do IMO not a fan of lightened flywheels.

Regarding TDI boxes the ratios are different to petrol you'd really have to be careful and make sure the ratios match or are very close.

ya ive been researching a lightened 7a and how to mount the speed/ TDC sensors for that i think i can either swap the 7a sensor bracket over or modify the stock one to swivel over.

[prosty]

Tighten the drivline is: Press the brake, release the clutch until it starts to grip, and you drop ~200 rpm from your idle, press the clutch back in, now all the gears and driveshafts are "tight" against each other and don't slam when you release the clutch from a 5000+ rpm banzai take-off.

If you want you can use the hand brake instead of the normal brake, but that's hard to do if you're on the dragstrip and lining up, at least if you want to go as soon as the light turns green.

I've tried the heavy shockproof, that's just too thick, but the lightweight version works absolutely wonderful in my trannies.

Hope any of this helps or sticks

[germantoy]

Tighten the drivline is: Press the brake, release the clutch until it starts to grip, and you drop ~200 rpm from your idle, press the clutch back in, now all the gears and driveshafts are "tight" against each other and don't slam when you release the clutch from a 5000+ rpm banzai take-off.

If you want you can use the hand brake instead of the normal brake, but that's hard to do if you're on the dragstrip and lining up, at least if you want to go as soon as the light turns green.

I've tried the heavy shockproof, that's just too thick, but the lightweight version works absolutely wonderful in my trannies.

Hope any of this helps or sticks

ya thats exactly what i do now ive been doing that for the past 6 months but i beat it before then oops . My car is actually going to be a test mule for a 4500 rpm motronic launch control.

Basically i think im going to buy a new mainshaft for my transmission and have it cryo treated and rebuild it when i have the money.

thanks agian for your help

[Gringo]

Shed some weight off your wagon Weight is the enemy in all motorsports. If your car was lighter the tranny wouldn`t take so much punishment. Go carbonfibre where you can, throw out everything you dont need ( ac, ashtray, powerwindows and your granny ).