What would it take to convert an 09SS to an AWD system? Besides loads of cash and all custom parts would it be possible to scavenge systems from a subaru or other factory AWD car?

 

you could probably find parts off of a saab and make them work

 

probably like $20k worth of work. You would have to be extremely in love with your cobalt to do this. Anythings possible with enough cash.

 

yeah maby u should try geting into a saab and get a transfter case and a tranny( if ur tranny wont work with the transfer case. a rear axel out of what ever car u rob or maby a custom one . if ur going awd i would worry aboutmoney more than anything .. also ur car is prob going to get hacked up a little bit to make this work( its like every first time u kind ahave to screw it up to figure out how to do it correctly.

 

This has been discussed before many times. Yes Saab does have a trans "THe Aero AWD" i will be trying to do this to my car once I figure some stuff out first.

 

Less then $10,000 if you do the work yourself.

 

I thought one of the biggest issues is there just isn't enough room in the rear for all the extra parts/room to run a driveshaft.

 

In the rear you'd need a fuel cell and to maybe massage the floor some. Driveshaft would run where the exhaust is and the exhaust would hang a bit lower to the right or left side.

 

doubtful. You aren't just going to bolt in the tranny, driveshafts and axles. It is NOT that simple.

 

used saab drivetrain... fuel cell/ tank relocation and custom fabbed exhaust.. if you can do it yourself.. yea you probably could

 

used saab drivetrain which will have to be hella modified to fit, suspension work, fuel cell, exhaust, likely custom axles, custom mounts....this is assuming you don't run into any unexpected problems, which is unlikely. When you go into a project like this, have double what you expect it to cost ready to go because you will almost never get it done within your original budget.

 

converting to rwd would be more practical.

 

Got VTEC!!!!! j/k




Its on my to-do list. I'm working with RIck on this.

 

converting to rwd is harder because you need to change how your engine mounts in a awd you dont

 

Yea in the many other threads they were discussing this and concluded that an AWD setup is better.

 

AWD setup is def cheaper and easier.

 

Screw $10,000. How about <$500.

http://kalecoauto.com/index.php?main...products_id=38

 

Actualy the transfer case from the AWD Montana minivan has the exact same bolt pattern as the output side of the Cobalt (they both use the same gasket) So there's the transmission side done. Also you could use the rear end from the same minivan as its built as a unit type piece tobolt into a flat floor. The only issues you'd need to address would be cutting the floor and making a bigger tunnel for the drive shaft and then having a driveshaft built. But you could probly also use the one from the van and have it shortened. Not sure if the width of the van and car are the same so you may have to wide body the car.

There you go, how to build a AWD Cobalt SS/TC.

 

Actualy the transfer case from the AWD Montana minivan has the exact same bolt pattern as the output side of the Cobalt (they both use the same gasket) So there's the transmission side done. Also you could use the rear end from the same minivan as its built as a unit type piece to bolt into a flat floor. The only issues you'd need to address would be cutting the floor and making a bigger tunnel for the drive shaft and then having a driveshaft built. But you could probly also use the one from the van and have it shortened. Not sure if the width of the van and car are the same so you may have to wide body the car.

There you go, how to build a AWD Cobalt SS/TC.

 

Don't forget the blinker fluid sale on that site too.

 

What the ****.............

 

The problem with using the Saab t-case as well is that it is a complicated, electronically controlled one IIRC.

Same Haldex set up as an Audi IIRC

 

Thats why I suggested the one from the Montana minivan! No electronics and it bolts directly to the passenger side of the transmisson case after removal of the the factory passenger side axle output. Not sure if you'd have to get the axle shortened or not tho as I never measured them. But the output gaskets are the same for both transmissions so the AWD splitter should bolt right up!

 

Not exactly sure where I should start with the whole AWD Cobalt but this eems like a good place.

The AWD U-vans come with a 4T65 trans, and the transfer case is designed for that trans. The Cobalt comes with a 4T45 auto. Not exactly sure what seal youre talking about that is the same, because the 4t45 and the 4t65 cases arent even designed the same....the passenger side extension of the 4t45 doesnt even come off!!!! Thats a bit of an issue since the transfer case bolts onto the that extension flange......but lets assume you can get around that......youll find the final drive differential is different, this is a big deal because the transfercase replaces the differential. So if somehow you overcame the issue that the x-case doesnt bolton onto the Cobalt automatic transmission youd still have the issue of......you need to convert to automatic........

Moving on, youd have to create a solution to either A: activate the electrically controlled rear viscous differetnial, OR B: convert that diff to self activating somehow....

Lets look at the rear drive from the van.....its independent suspension, so you need to mount the differential to the chassis somehow IE: you need to design and fabricate a rear subframe.

Youll also need to design and fabricate a completely new rear suspension, including control arms, mounting points, dampers, springs, uprights and of course youll need axles.

As mentioned you need to remove and relocate the fuel tank(and EVAP systems, if you want to have any chance of being legal)

You need to relocate the exhaust. which is of course easier said than done, youll need to enlarge the floor tunnel, all the way back and fab full custom exhaust since it will now go a whole new route and has to deal with swinging drive axles.

Lets get to what is really the true problem.......if you somehow overcame all the above issues, and still were sane and had money left......Youd still have one last major issue......

The Cobalt uses a frame mounted rear positioned steering rack!!!!!!!!!!!!!!!

Your transfer case want to go right through where the rack lives........

Sooooooooooooooooooooo............

You need to completely reengineer the steering system, moving the steering rack to the front of the subframe,relocating the forward trans mount, designing and then forging new front steer arm knuckles, in the process most likely changing from a leading caliper brake system to a trailing caliper position, and replumbing the brake system. And youd still have the transfer case hitting the subframe so youll just be making a new one of those anyway.


Yeah.....this sounds WAAAAYYYYYYYY easier than RWD.