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Great News! Found the official specifications for the D16...

Well it's not so great. The transmission can only take 135 ft-lbs at the input shaft. That would probably explain why Nemasys blew his D16 to pieces when he went to the drag strip.

linky!

http://archives.media.gm.com/us/powertrain/en/product_services/2010/gmna/Spec%20Sheet/Transmissions/2010%20Manuals/10_D16_MLL_n_.xlsx

What happens if I changed the final drive ratio to a bigger one? Will it increase the tolerance or decrease the tolerance?

My car had 205Nm (approx 151 lbft) dynoed on the wheel and had been running for one year plus without problem from gear box. I almost red line every few day once at least for some traffic light to traffic light drag with bigger 2000cc cars or 2400cc cars or those 3000cc diesel taxi.

The tolerances are fixed when building the transmission. Meaning, it can take 135 ft-lbs everyday and last for the lifetime of the vehicle. That said, if you put more power through the transmission than what it was designed for, you are reducing its lifetime. There is no way to predict when the transmission will let go.

In your case, sure, your engine puts out 150 ft-lbs, but that's not the whole story. That is only peak torque. The average torque you put through the transmission might only be 50-80 ft-lbs while driving normally, therefore making the transmission last longer than it should.

The final drive has nothing to do with engine torque. It changes the output speed at the wheels. In your case, your also putting more stress on your drive shafts.

intersting

I didnt blew the the transmission, i broke the casing of the gearbox because of wheel hop.

The d16 can take well over 200 whp, some ppl from overseas have turbo'ed deawoos with the d16 and have no problems with it.

When i changed my d16 to the d20, i opened it up and the internals were not damaged whatsoever. The lower engine mount that bolts to the transmission broke, thats what happened. The casing broke where the mount bolts into.

Well that's good to know. Although it seems that the Aveo could use better mounts... Feels like the engine is all over the place in the Aveo, and when I drive other cars, I immediately notice how "tight" the engines are. Response is better and it doesn't jerk you around.

engine mounts will be my next project, because with all the talk i can see they need done,

I also want to make them stiffer, ill be using a hockey puck cut with a rotary tool then use some epoxy glue and some good silicone to seal it off so it wont come out due to vibration.

i want an complete redesign, the way the side mounts are now (the post through a circle) leaves all the torque to be controlled by the lower dogbone, which is also a weak design. If you change the design, it will improve wheel hop and also take some of the burden off the dogbone.

i will be making a side mount like this which will not twist:

sweet