6266 Build or Bust

[1cleangsx]

Got my control arms a couple weeks ago from Volk, they look even nicer in person.

Install wasn’t too bad except the passenger side was a b!tch. Anything aftermarket doesn’t quite fit like oem, but I love these and glad I got them. I got the diff mounted up today as well, the BSFab mustache bar was a bust. Even after loosening the stud hangers for wiggle room it just wouldn’t mount up. One side slid right on, the other not so much, I actually got it stuck and was a pain to get it back off, so the oem one went back on like a glove , I don’t mind it one bit.

Its progress

 

[92AWDHX40]

Yeah im running volk toe eliminator and uppers really nice stuff. Picked up his prototype cross member kit to.

 

[1cleangsx]

Nice!

 

[1cleangsx]

Hey guys not much of an update, just wanted to share a pic of these nifty lifting brackets I just got from Boosted Fabrication! Can’t wait to order my trans mount/bracket from these guys, anyways

I got a front/rear engine lift bracket, and of course their auto trans lift bracket and their clutch master cylinder block off plate to finally finalize the remaining 5 speed history of the car

 

[1cleangsx]

Well I finally got the motor out last weekend and slowly tore it down through out the week.

Now for the fun part , I was excited to see how everything looked after making some power, again this engine only has 1300 miles on it.

No issues with the headgasket, this thing only saw 39 psi on a 6266, I know people have run way more boost on much bigger turbos with these gaskets, I’m definitely a fan of them .

The head looks good, time for the block.

The worst wear was on the main journals of the crank, nothing that my fingernail would catch.

And on to the rods.

So nothing looked catastrophic, this engine had normal oil pressure its last idle and sounded fine, I just wanted to tear it down to be on the safe side, and I’m no expert on the journal wear, my brother n law said it doesn’t look bad, I’m hoping it can be polished and re used, I’ll also be upgrading to some “turbo tuff” 21mm .250 wrist pins.

Yesterday I removed all four broken oil squirters, I have the 12mm x 1.25 plugs on the way

 

[1cleangsx]

Oh yeah and I’ll also have my oil pick up modified

 

[Anfurnyy]

No issues with the headgasket, this thing only saw 39 psi on a 6266, I know people have run way more boost on much bigger turbos with these gaskets, I’m definitely a fan of them .

I love mine so far, only annoying thing is REQUIRING the deck to be milled Everytime you pull the head.

 

[1cleangsx]

Right, I knew I would be taking both the block and the head in for servicing so it wasn’t a big deal.

Once I get my oil squirter delete plugs in, I’ll be bagging everything up for the machine shop in October/November, then I’ll be tearing into the w4a33 , I’m going with an IPT re build kit, attacking that this winter, and hopefully have the car back on the road in its refreshed, automatic glory by spring of 2026

 

[DreamChaser7]

what was the reason for tearing the engine down? What head gasket is that?

 

[1cleangsx]

I tore it down because all 4 of my oil squirters broke off at some point, and despite oil changes every 50 miles or so I would still see a few specs of material here and there in the oil, so hoping to re use my crank, rods and pistons I tore it down to be safe The head gasket is a SCE Vulcan Cut Ring, it’s basically just a composite with SS rings that seal the combustion chamber, the rings actually have a slight protrusion that bites into the head for a better seal, but like Anfurney said it does require decking the head each time, but I’m still a fan of them

 

[1cleangsx]

Got the oil squirters blocked off

Next up.. the w4a33 journey begins

 

[1990TSIAWDTALON]

Those bearings don't look bad. Polish your crank with a long strand of 320 emery cloth and WD40. It will look and feel like new.
Forgot to add, then measure it.

 

[1cleangsx]

Thanks for the advice Marty! I will however be taking the block/head and rotating assembly back to the same machine shop I always use, the trans however I will be attempting on my own , the valve body will go to Aaron Gregory, Center Diff and converter will go to John at IPT

 

[1990TSIAWDTALON]

Well I'll follow along on the trans rebuild and see if I can duplicate it for the new car I somehow got. I have a welded center dif already to go. Keep us updated

 

[1cleangsx]

Will do! And congrats on the new car!

 

[1990TSIAWDTALON]

Its a curse Jeremy........
Did you EVER figure out why you were breaking your squirters

 

[1cleangsx]

Nope, maybe vibration? I’ll never know for sure, but I am pretty sure with forged pistons and e85 I don’t NEED them anyways

 

[1990TSIAWDTALON]

I assume vibration also. When I open up my other block, I'll be looking to see if any survived too.

 

[1cleangsx]

Actually what’s funny is with a fluidamper and factory motor mounts, I don’t feel any engine vibrations behind the wheel at idle despite balance shafts deleted, however the engine certainly moves a good bit at high rpm pulls as you could see in the dyno video

 

[1990TSIAWDTALON]

I know the "feeling". I have ProThane mounts and no balance shafts BUT had the bottom end balanced.

 

[1cleangsx]

Just pulled the pan along with a few other components, no metal chunks so that’s a plus

Stay Tuned!

 

[1cleangsx]

Made some progress today on the tear down, got the valve body out and wrapped up to be shipped out in October.

Despite how dirty this thing is on the outside it looks nice and clean on the inside .

Next up I tackled the pump removal, I followed the tips of an old thread on here for a kiggly 5 friction install and used some oem main bolts to back the pump out.

It came out fairly easy.

That left me staring at my front clutch basket, the next few parts came out very easy.

Hard to believe these are 35 year old parts, Friday I ordered the hard copy of the ATSG manual that’s on w4a33.com, found it on eBay for $20 bucks , before I continue on I’m gonna practice re installing these 5 parts to learn before I dive in too deep , I’m having fun tho

 

[CrackedDSM]

Good times, those look great.


The snap ring that holds the rear clutch pack assemblies in is an absolute bi*** to get back in though.

God I miss owning an Auto.

 

[1cleangsx]

I’m loving everything about it so far , I’m excited to hopefully enjoy 6266 power without losing boost between shifts, and being intimately familiar with the transmission that provides that

 

[1990TSIAWDTALON]

Doing good Jeremy! That old fluid was dark so I'm sure some fictions were getting old and thin. Your gonna love it!