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Old 04-19-2008, 06:49 AM   #1
Bilyk WRX
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Default Ppg Failure!!! Straight Cut Synchro

This happend yesterday.
The car is GC8 with Axis Stage 5 and Innovative GT74 turbo, 5 speed sychro straight cut PPG 1-4 gears
The second gear tooth just fell off on road in the city on 1 bar of boost on 93 ron with 11:1 AFR
This box had only 10-15 drag strip passes.





THE CAR:

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Old 04-19-2008, 08:11 AM   #2
Nate8409
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Ouch.
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Old 04-19-2008, 12:42 PM   #3
hybrid gti 2
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Yea and how much power are you putting down?
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Old 04-19-2008, 01:47 PM   #4
keaniegenie
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What's so strange is I've never seen a PPG helical synchro set break which is supposed to be the weakest one.

Sorry to hear.
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Old 04-19-2008, 02:11 PM   #5
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isn't 93 ron worse than what we get here? oh and sorry about the break
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Old 04-19-2008, 02:15 PM   #6
Bilyk WRX
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Last year this car did 11.5 on 1.2 bar with alky on 5mt (sti ver6)
and 10.8 on 1.7 bar with alky on AUTO tranny
never been to dyno
PPG was installed 2 weeks ago.
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Old 04-19-2008, 02:17 PM   #7
Bilyk WRX
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Quote:
Originally Posted by phillepe View Post
isn't 93 ron worse than what we get here? oh and sorry about the break
we have here 98 RON it corresonds to 93 RON in US, so I sad it was 93
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Old 04-19-2008, 04:55 PM   #8
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question now is....are they replacing the gear for no charge?? I can only imagine they will, but it's never really come up before since this is the first documented break.

Keep us up to date.
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Old 04-19-2008, 05:00 PM   #9
flstffxe
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By the looks of the break it doesn't appear to be a material issue(tooth next to it with a impact mark held up ok) but a metal fatigue issue. There is no slow crack development, indicated by growth rings(like on a tree). It only has the looks of a sudden break(sandblasted or sandcast look). Meaning it was just pushed up to its working load limit and then sheared off. Not that surprising with that number of strip runs on it. Some info on metal fatigue from wiki, enough for you to get the idea.
http://en.wikipedia.org/wiki/Fatigue_(material)
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Old 04-19-2008, 05:15 PM   #10
nicholam
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Quote:
Originally Posted by flstffxe View Post
By the looks of the break it doesn't appear to be a material issue(tooth next to it with a impact mark held up ok) but a metal fatigue issue. There is no slow crack development, indicated by growth rings(like on a tree). It only has the looks of a sudden break(sandblasted or sandcast look). Meaning it was just pushed up to its working load limit and then sheared off. Not that surprising with that number of strip runs on it. Some info on metal fatigue from wiki, enough for you to get the idea.
http://en.wikipedia.org/wiki/Fatigue_(material)
I agree with everything you've said except that last part about not being suprised. If this is the first set ever to break then it must be one hell of a suprise. Personally, if I spent that kind of money on a transmission with the intention of racing, I'd hope I'd get more then a dozen runs out of it.
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Old 04-19-2008, 05:33 PM   #11
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Quote:
Originally Posted by nicholam View Post
I agree with everything you've said except that last part about not being suprised. If this is the first set ever to break then it must be one hell of a suprise. Personally, if I spent that kind of money on a transmission with the intention of racing, I'd hope I'd get more then a dozen runs out of it.
+1 I'd expect to make a dozen runs on a stock 5 speed
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Old 04-19-2008, 05:53 PM   #12
Str8Gone
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Its definitely not the first break, helical and straight cut are damn near the same strength as told to me by Andrewtech.
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Old 04-19-2008, 07:02 PM   #13
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And who installed this gearset?
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Old 04-19-2008, 08:38 PM   #14
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Quote:
Originally Posted by Unabomber View Post
And who installed this gearset?
Regardless of who installed it, from what I know, its the first PPG failure I've ever read about.
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Old 04-19-2008, 09:24 PM   #15
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Quote:
Originally Posted by 2ndGearFling View Post
Regardless of who installed it, from what I know, its the first PPG failure I've ever read about.
Well if i installed my ppg's or had andrewtech install them. Which set has a chance to break first.
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Old 04-19-2008, 09:29 PM   #16
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No, there have been a few failures, but none yet due to power. It's always been install and there were some other warranty issues.
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Old 04-19-2008, 09:31 PM   #17
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Quote:
Originally Posted by Unabomber View Post
And who installed this gearset?
Exactly! The PPG gears aren't just drop in gears. There is a lttle more to it. They have their own specifications and if the intsall is not done properly this can happen.
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Old 04-19-2008, 10:56 PM   #18
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Quote:
Originally Posted by jbwrx View Post
Exactly! The PPG gears aren't just drop in gears. There is a lttle more to it. They have their own specifications and if the intsall is not done properly this can happen.
This is what makes it so difficult to buy these things. They are already expensive as it is, and yet they are the only ones that seem to know how to install them properly. Might as well put the installation of these things into the price tag and call it 6000 instead of 5000 for them.
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Old 04-19-2008, 11:25 PM   #19
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meh.... nothing is unbreakable... Perhaps there is something about the conditions under which the gears were used that caused their demise... for example, was driveline slack taken up on the dragstrip before the launch?
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Old 04-19-2008, 11:33 PM   #20
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Quote:
Originally Posted by sleeperrex View Post
This is what makes it so difficult to buy these things. They are already expensive as it is, and yet they are the only ones that seem to know how to install them properly. Might as well put the installation of these things into the price tag and call it 6000 instead of 5000 for them.
Dont blame Andrewtech or PPG they dont make you do anything. They sell a product and they happen to be the best at installing the product. You as the customer choose to not use the best. You get what you pay for. FWIW their install fee is worth the piece of mind IMO.
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Old 04-19-2008, 11:55 PM   #21
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Yeah I would have had Andrewtech install the gearset myself. It is your choice. BUT, look at that carnage..er..more like a paper cut. That gear busted ONE tooth off.
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Old 04-20-2008, 12:13 AM   #22
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I want to know what the resolution to this problem will be. Any word from PPG on these gearsets? Any word from AndreTech? Has this happened ever before? History on this gearset - where it came from (vendor), who installed it, was it new, ect. Hook us up with all background info.
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Old 04-20-2008, 10:07 AM   #23
JonR
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Didn't you have an APS gearset and break the main shaft also?

As others have asked, who installed the gears? If not Andrewtech...I've heard so many other horror stories about "my local transmission guy" installing new gears and messing stuff up.
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Old 04-20-2008, 12:02 PM   #24
hybrid gti 2
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^ true
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Old 04-20-2008, 12:42 PM   #25
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Quote:
Originally Posted by Unabomber View Post
And who installed this gearset?

+1

waiting for reply now
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