19bonestock88's 2004 Saturn "Ion Green Line" build...

[19bonestock88]

I am on a 205/65 tire, though I half contemplated trying out a 205/70 to see if I can handle the diameter... goal is to be below 2000 RPM on the freeway at 60mph

[mpg_numbers_guy]

You'll be just barely beating that with the new trans. 205/65R15 tires with a 3.63 FD and the 0.69 5th gear puts you at 60.58 MPH @ 2000 RPM.

With the stock trans and 205/65R15 tires you're at 57.26 MPH @ 2000 RPM.
An Insight is 58.56 MPH @ 2000 RPM.

[19bonestock88]

Nice! Looks like with the FY1 trans I’ll be damn close to my goal too! Ideally I’d like to land at around 1900 or so, you know, below 2k enough you can tell on the gauge lol

[roosterk0031]

I 've thought of going up to 205/x for summers but haven't yet. Cheap summer tires to save the expensive tires for winter.

[19bonestock88]

They work fine on my car, I think I gained a bit of mileage from the larger diameter. Handles great on a 205/65 tire, though it’s worth noting that I’m on Cobalt SS/TC suspension which is much much firmer than stock and I run them at 50-55psi both to lower rolling resistance and to tame sidewall flex... with a stickier compound than the LRR stuff I’m running this thing would truly be a weapon in the corners

[19bonestock88]

So, my transmission swap saga has begun with a broken transmission! I get another transmission and go to swap it in, finding numerous problems along the way. First, the front transmission mount is different between the M86 and the FY1 transmissions. However, Getrag left the casting nub in place where the mounting hole was for the M86 transmission, and two of the other bolt holes lined up. Solution- drill and tap the transmission case for a similar sized bolt (3/8” instead of M10 but it’s a minor difference). (pic included)

Second problem was that the slave cylinder on the M86 transmission(which mated up with the stock clutch line) was bad, so we used the slave cylinder from the FY1 transmission, but it didn’t mate up with the stock clutch line, the nipple on the end was different. Solution- cut off the stock M86 clutch line nipple and heat the nylon line with a heat gun, press the cut off FY1 clutch line nipple into the line, no leaks and it mated up perfectly with the FY1 slave cylinder, that appeared new.

Third problem was that the transmission was supplied with a crusty looking roll pin in the linkage, that I had no idea the lifespan of. Solution- cut out the roll pin with the micro Dremel and replace it with a further hardened version of the Clevis pin that was in my shifter. It was actually a bit larger in diameter, now an interference fit which required a hammer and grease to install. The result is shift action that’s firm and super precise with no slop whatsoever, a pin that should never break no matter what I do to it, and a spare pin to keep in the glove box just in case I was wrong.

We also installed my OTTP control arm bushings, as all of the ones on the car were wasted, possibly damaged from the 30mph driveline lock that occurred when the previous transmission decided to grenade itself. Now all the control arm bushings are solid pieces, with no flex whatsoever. More linear and precise suspension travel, yadda yadda...

We filled the transmission with fluid and bled the clutch, buttoned everything together, fired the engine, everything was looking good. Took it for a test drive, car handled great (though alignment was noticeably off), transmission shifted great, I was happy and all was going well...




Until I quickly discovered the final problem, which isn’t solvable yet. I got onto the throttle coming out of a tight curve, and found some NASTY clutch slip. Apparently, my pressure plate had worn at a similar rate as the original slave cylinder (which was bad), and when paired with a new, firmer slave cylinder, doesn’t provide full and complete clutch engagement. It’s good enough to slowly move the car on flat ground, but anything over about 22% throttle angle makes it slip badly. At one point I had it up near the limiter in 5th going 55mph, just by stomping the accelerator. We reused the original clutch and pressure plate for no other reason than I couldn’t afford to swing the cost of the replacement and to pay for all the labor too. I figured that if it hadn’t begun slipping I still had some life left. Wrong again! Now the mad scientist and I have to rip it all back apart and replace the clutch that I fried... (vague Vin Diesel reference)

Anyway, tune in next week for the next episode of “will this thing ever drive again?”

[19bonestock88]

So, I got my new clutch kit in the mail, meant for a 2009 Cobalt, so as soon as my mechanic is free again we can try and get this thing on the road...

As an extra note, I’m still working on modding her even while she’s down. What I’m currently working on is a OG VX style trailing edge fender vent to go on when I swap the Redline front clip on (I want the look and its projector retrofitted lights).

I began by measuring and marking off a piece to cut out of the fender (pic included)

Then I cut out the pieces, took them home and transferred the shape roughly into coroplast (my EcoModding material of choice as it reduces the costs of these mods to near free), as well as defining the shape of the part that will actually attach to the fender

Next, I have to cut the filler pieces to hold the vent open and hopefully to a inward curve of some kind (better to extract the fenderwell air with) and then fasten the whole thing together and prepare it to be attached to the fender

Tune in next week for the next episode, when I maybe get to drive the thing and I keep aeromodding the Redline front clip I plan to swap on. I’ve got a bumper cover with way too many grille openings and some fake scoops on the sides which I plan to turn into functional air curtains, and maybe add some kinda air dam if I get a chance

[19bonestock88]

Well it’s not next week but I have more progress on the aeromodding of my new front clip that I feel good about. I finished my OG VX style fender vents and have them attached to my next set of front fenders, awaiting some paint. Aside from being made from scrap bits of coroplast I don’t think they look awful. Hopefully when I have the car up and going I can tuft test my current setup and then the new setup to reflect any differences. I’m fine with them as long as they don’t hurt aero any, they look pretty cool as they are, and I’m hoping for a modest 1-2% gain...

[19bonestock88]

The FY1 trans swap is complete. The new clutch works fine, just need to not beat on it too hard until it’s properly broken in. My clutch pedal is junk and gave us issues seeming like a bad master cylinder until we looked closely.

My alignment is wrecked again, it was set based on loose and floppy rubber bushings which the front end no longer has. It also wrecked my front tires so I have two random tires in the proper size in place for now, until I can get it sorted.

The solid bushings make the thing super responsive and super precise and it’s possible to achieve cornering speeds that would terrify any sane individual, however it rides a little more firmly now (oops lol)

The gearing is terrific, though I give up use of 5th in town due to my fifth gear after tire size correction being half a hair more than 30mph per thousand RPM. 25 is just too slow to spin the engine under load in top gear. It’s worth noting that the shift up light no longer functions, presumably because the PCM doesn’t recognize the gear ratios anymore

Picture was taken from my phone mount, at an indicated 60mph, which was an actual speed of 63-64...

With alignment whacked and me sorting clutch issues I haven’t gotten any readings on mileage but it should be great with the car all dialed in

[19bonestock88]

I now have put 2,000miles on the new setup, though most of that was commercial use. It’s also gotten cold enough that in personal use my engine temps hover in the range of 180F. Mileage is in the toilet as a result. My alignment still needs corrected, but I’m now dealing with issues with my gauge cluster. The lens cracked the other day and some of the lighting has gone off. If I didn’t have a perfectly good cluster in my Ion Redline parts car I’d probably just glue the lens and replace a couple bulbs, but I decided to go down the rabbit hole of swapping the whole cluster. I plugged it in to verify function and all I need is to visit the local GM dealer to get the odometer married to the BCM in my car and I’ll be all good. I did customize the face of my cluster to reflect the mission of my car, more pics when it’s installed and working!

It’s also worth noting that I’ll have them calibrate the speedometer to my current tire size so I can stop guessing at how fast I’m actually going lol