F40 6spd conversion research

[woody90gtz]

I broke my Muncie 282 5spd at the track, so I'm thinking about an F40 6spd upgrade. It will be going in a 3400 Beretta. I'm not worried about the fab work for a custom mount or the intermediate shaft...my main concern will be the cost of clutch, axles and LSD.

I know V8Archie sells a clutch and flywheel spacer kit for about $800. Right now I have a good SPEC 2+ for the 282, but from what I understand, the input shaft splines are different.

I currently have Driveshaft Shop 282 axles, and they said they could either convert mine or go all new for about another $800. I read about using the 282 outer CV and the F40 inner with a custom bar from Moser and the like. Do you need a donor F40 axle or are the inners available new?

I assume the F40 never came factory with an LSD. Is that correct? I've found a Quaife LSD for about $1000. Does anyone convert a stock diff to LSD similar to what EP does?

Thanks for any help.

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[Joseph Upson]

I broke my Muncie 282 5spd at the track, so I'm thinking about an F40 6spd upgrade. It will be going in a 3400 Beretta. I'm not worried about the fab work for a custom mount or the intermediate shaft...my main concern will be the cost of clutch, axles and LSD.

I know V8Archie sells a clutch and flywheel spacer kit for about $800. Right now I have a good SPEC 2+ for the 282, but from what I understand, the input shaft splines are different.

I currently have Driveshaft Shop 282 axles, and they said they could either convert mine or go all new for about another $800. I read about using the 282 outer CV and the F40 inner with a custom bar from Moser and the like. Do you need a donor F40 axle or are the inners available new?

I assume the F40 never came factory with an LSD. Is that correct? I've found a Quaife LSD for about $1000. Does anyone convert a stock diff to LSD similar to what EP does?

Thanks for any help.

You can buy a one piece aluminum flywheel for about the same price maybe less and have a tailored fit.
http://imageshack.us/g/17/clutchflywheel1.jpg/

You may also be able to use an axle set from the supercharged cobalt and saturn depending on track width or at least possibly have a combo arrangement using them. Only the supercharged models have the correct spline count and size.

The Ford Focus and Ranger clutch disc around mid to early 2000 has the proper spline count for the clutch disc or you can have a custom disc made at a local supplier.

[woody90gtz]

You can buy a one piece aluminum flywheel for about the same price maybe less and have a tailored fit.
http://imageshack.us/g/17/clutchflywheel1.jpg/

You may also be able to use an axle set from the supercharged cobalt and saturn depending on track width or at least possibly have a combo arrangement using them. Only the supercharged models have the correct spline count and size.

The Ford Focus and Ranger clutch disc around mid to early 2000 has the proper spline count for the clutch disc or you can have a custom disc made at a local supplier.

That flywheel is pretty sweet. Where did it come from? And is that a Muncie pressure plate? It looks similar to my current SPEC 2+. If I can use my pressure plate and good disc from a Ranger I may be able to do this on the cheap.

According to Napaonline the driver's Cobalt SS axle is 7/16" longer than the Beretta...but perhaps the bar could be shortened slightly. And the pass one appears to be a long axle with no jackshaft.

[Joseph Upson]

That flywheel is pretty sweet. Where did it come from? And is that a Muncie pressure plate? It looks similar to my current SPEC 2+. If I can use my pressure plate and good disc from a Ranger I may be able to do this on the cheap.

According to Napaonline the driver's Cobalt SS axle is 7/16" longer than the Beretta...but perhaps the bar could be shortened slightly. And the pass one appears to be a long axle with no jackshaft.

The passenger axle has an intermediate shaft and the poster of those pictures should have an associated email address on that site I would think, if not I'll try to get in touch with him. I forgot the name of the company that made the flywheel for him.

[woody90gtz]

I know the F40 has a jackshaft stock, but the Cobalt pass axle is very long so it must not have a jackshaft. Maybe I could use the long axle on the F40 without a jackshaft.

I couldn't find a user name for that photo, but I left a comment asking where it came from.

[robert 1980]

So what are your plans for the engine?lol

[Joseph Upson]

I know the F40 has a jackshaft stock, but the Cobalt pass axle is very long so it must not have a jackshaft. Maybe I could use the long axle on the F40 without a jackshaft.

I couldn't find a user name for that photo, but I left a comment asking where it came from.

I was speaking of the Cobalt having an intermediate shaft and I'm pretty certain it does and it's female ended vs. the male ended G6 intermediate shaft. It should have near the exact same arrangement as the Saab 9-3 which both trannies were used on if I recall correctly.

The flywheel owner is a member here, scroll down for his post, http://60degreev6.com/forum/showthre...ight=g6+clutch

[woody90gtz]

Thanks for the thread. That's a good read.

I called Clutchmasters and they said that flywheel was a one-off that would cost about $700 for a copy of it, and more like $1000 if I needed any changes to the design.

Does the 3900 share the same crank mounting flange as a 3400 and would they be interchangeable? In other words, could a 3900/F40 car use the same 3.1 flywheel and V8Archie spacer & clutch setup as a typical Fiero would?

[Joseph Upson]

Thanks for the thread. That's a good read.

I called Clutchmasters and they said that flywheel was a one-off that would cost about $700 for a copy of it, and more like $1000 if I needed any changes to the design.

Does the 3900 share the same crank mounting flange as a 3400 and would they be interchangeable? In other words, could a 3900/F40 car use the same 3.1 flywheel and V8Archie spacer & clutch setup as a typical Fiero would?

As far as flywheels are concerned, whatever bolts to the 3400 will bolt to the 3900. It's just a bored and upgraded 3500 that's all.

[woody90gtz]

As far as flywheels are concerned, whatever bolts to the 3400 will bolt to the 3900. It's just a bored and upgraded 3500 that's all.

That was my assumption, but wanted to make sure. So that same custom flywheel would work for me, but at $700 it's not cost effective, when I can use my flywheel and a $375 spacer from V8Archie instead. I'm sure it weighs a few pounds less, but nothing I'm concerned about.

It appears to be big money to swap an F40 no matter how you slice it. Seems the upgrade might not be worth the extra investment.