FORD SIERRA 1983 1.G XR4 Workshop Manual

PERFORMANCE & SERVICE
PARTS GUIDE
Merkur XR4ti / Sierra XR4i / Sierra RS Cosworth / Sierra RS 500 / Merkur Scorpio
CATALOG 08/2002 EDITION
BAT BATBAT BAT
BAT Inc.
British American Transfer Inc.
7630 Matoaka Road
Sarasota, FL 34243
phone (941) 355-0005
fax (941) 355-4683
www.batinc.net

Introduction0 1
BAT BATBAT BAT
BAT is pleased to be able to offer this line of components
for the U.S. specification "Merkur" XR4ti, Scorpio and the
other European models of Sierra lineage. European Sierra
models have been manufactured since 1982 and include
two versions or body styles. We will concern ourselves with
the Mark 1 as it is more similar to our U.S. version. The high
water marks of the MK1 series are the XR4i and the Sierra
Cosworth and R/S 500 models. From the exterior, XR4i is
very similar to the U.S. Merkur XR4Ti in overall looks.
However, under the hood it is powered by a 2.8L V-6 engine
where we have the 2.3L 4 cylinder turbo. The other notable
MK1 car the Cosworth Sierra is simply one of the more
outrageous vehicles Ford has ever offered. The Cosworth
starts life as a base Sierra three door body shell and adds a
high performance engine, suspension, transmission, and
aerodynamics, making it one of the fastest 4 passenger road
cars in the world. Power comes from a 2.0L Cosworth Turbo
YB series engine rated at 205 h.p. in its base form, and
upwards of 550 h.p. in modified rally form. The R/S500
homologation outgrowth of the R/S Cosworth version is
basically a de-tuned race car in street trim. Sierra MK2
versions received a sheet metal make over but share most of the mechanicals of the MK1. Interesting MK2
Sierra's include the Sierra Sapphire Cosworth, and Sierra XR 4x4 - an advanced 4 wheel drive 4 door sedan.
What all this Sierra history means to us is an abundance of specialized
performance parts, many of which bolt-on to our U.S. spec. Merkur. With
this in mind Merkur owners can make an good vehicle even better. It is
very amusing how much attention a Merkur that has been outfitted with
Ford badges and Sierra logos and Cosworth grille commands, let alone
a car equipped with the complete Cosworth body work!
BAT BATBAT BAT
BAT is a recognized Ford Motorsport USA and Ford Motorsport/
Rallysport European dealer with over 30 years of experience of tuning
European Ford automobiles. From Cortinas, Lotus Cars and Anglias
during the 60's through the 70's with Pinto and Capri and into the 80's
and 90's with Fiesta, Escort and Merkur. Our expertise with building and
racing 4 cylinder Ford powered cars includes Formula Ford, Formula
Continental & Atlantic, SCCA Production, Showroom Stock, Auto-X,
Improved Touring and Circle Track racing classes. We have a highly
capable staff and you can confidently allow them to handle even your
most difficult technical needs. Better still, our ability to buy in quantity,
import products directly, and manufacturer speciality components
assures you are getting the right parts at the right price
.
P.S. We have recently added a considerable number of parts for the Merkur Scorpio. Most of the XR4 items
will have a Scorpio alternate available. See the price list for more information. You can also view and
download updates to this catalog from our web site at www.batinc.net
Peter Thompson Eric Odenweller
and the staff at
BAT BATBAT BAT
BAT Inc.

pC pB
pD pJ
pK
pE
pJ
pG
pI
pF
pH
Suspension - (front)0 2
pA
sway bar bushings
(see page 4)
pF Front Control Arms higher mileage cars exhibiting ball
joint and bushing wear can benefit from our standard control
arms. These arms are brand new, and include ball joints and
bushings installed.
Note: the outboard (sway/control arm) bushing
is an uprated "castellated" design which transmits less vibration
than the original U.S. spec. bushing.
(left) M428L
(right) M428R
pG
Inner Control Arm Bushing H.D. Made from
increased durometer rubber, these heavy duty (GPN) bushings
offer the desired firming effect while retaining a reasonable
degree of shock and vibration absorption. (each) M428BH-N
Optional urethane version of above bushing(set) M428BU
pH
Control Arm/Sway Bar Bushing Kit This heavy
duty urethane bushing set really does an excellent job
limiting the amount of "jutter" felt at the steering wheel
which is especially noticeable under braking. The kit includes
bushing halves and center sleeves to do both sides of the
car and is easy to install.
(set) M428BK
pH
Control Arm/Sway Bar Bushings As an option to
urethane bushings we offer either the "castellated" type
outer TCA bushings are available in standard rubber, or the
new style (better fills the void between the bushing halves)
H.D. GPN bushing kit. Both will dramatically reduce the
vibration under braking common to XR's and Scorpio's.
Outer TCA Bushings Standard (pair) does 1 armM428B
Outer TCA Bushing Set H.D. (set)M428BK-N
pI
Sway Bar Washer Get the most from your new
"castellated" type outer TCA bushings by using this "shallow"
washer (in front behind the lock nut) for a tighter fit.M407W
pJ
Tie Rod Ends High quality European Ford standard
replacement tie rod ends. (left) M434L (right) M434R
pK
Front Strut Upper Insulator H.D. Made from increased
durometer rubber, these heavy duty (GPN) Insulators offer the
desired firming effect while retaining a reasonable degree of
shock and vibration absorption. Steering and transitional
response becomes noticeably more direct.(each) M404 pA
Front Sway Bar The larger Cosworth Sierra 28.5mm
factory front sway bar is a direct replacement for the standard
25mm bar.
(H.D. bar clamp bushings are included)M407
NOTE: see price list for sway bar clamp bushings for XR & Scorpio
pB Spring Sets see page 3 (spring section) for listings
pC Front Struts (see below- shocks sold as each)
Spax TA series struts utilize a non pressurized gas over oil design
with 10 positive settings (knob type external adjustment on top) for
tuning the dampening to suit individual applications.M401A
Spax Sport One of the most popular shocks we sell, Spax fixed rate
gas sport shocks are an excellent choice for upgrading the handling
performance on the XR. M401V
Bilstein New for 2000. Bilstein's new sprint series gas shocks
offer the big B's renowned German made performance at a very
attractive price. Bilstein shocks are now available in our
suspension kits see page 3 for details.M401B
Rally/Sport Super-Gas made to European Ford spec. by Koni of
Holland. R/S shocks feature Konis twin-tube low pressure design and
have adjustable settings (knob type external adjustment on top) which
can be tailored to suit individual applications.
M401RS
Boge Turbo-Gas German manufactured twin tube high pressure
gas design utilizing a unique variable valving system that insures
the perfect balance between ride comfort and road holding
capability.M401S
DeCarbon French made mono tube high pressure gas shocks with
fairly sporty valving, similar in design to Bilstein.M401G
KYB GR2 gas struts are high quality, heavy duty units that are
a cost effective performance upgrade for the XR4. Handling is
improved without sacrificing ride quality.M401Y
pD
Steering Rack complete rack assembly w/inner tie rods,
boots, and stainless steel inner sleeve. M434SR
pE
Rack Boot* replacement steering rack boot M434RB
*same boot left or right XR4 & Scorpio
Shock Absorbers
GAS SHOCK ABSORBERSSUPER
GAS SHOCK ABSORBERScheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items

Suspension
pC Camber Shims
pD Front
Strut Tower Brace
pE RearpA
Suspension Packages -XR4
Below is a listing of shock and spring packages available as engineered
suspension packages. Fixed rate or adjustable shocks are supplied as noted.
More information on the shocks that make up these kits is listed elsewhere in
the front and rear suspension sections. Kits are available with either -25mm
or standard ride height sport springs- your choice same price !
Spax Sport Gas Shocks & Sport Springs (-25mm or Standard) M400S
* supplied with fixed rate high performance gas shocks
Bilstein Gas Shocks & Sport Springs (-25mm or Standard) M400B
* supplied with fixed rate high performance gas shocks
Spax Sport Adjust Shocks & Sport Springs (-25mm or Std.) M400A
* supplied with adjustable high performance gas shocks
pB Sport Spring Sets -XR4
Our specially designed progressive rate sport springs will minimize body "roll" while
cornering and reduce "dive" under hard braking. Progressive springs are designed to
become stiffer as they are compressed allowing for a smooth transition between (very
reasonable) straight line comfort and high performance cornering. We recommend
the standard height or -25mm ride height sets for all around performance street and
light competition use, the -40mm springs should be considered for only racing/
competition use. Take into account when lowering your cars ride height that additional
negative camber will be added to the front and rear suspension angles. This is usually
not a problem on the front end, however, cars that are already experiencing noticeable
wear on the inside edges of the rear tires at "standard" ride height will see this increase
when lowering. This condition can be corrected if necessary by using camber shims
(kit available below) at the rear spindle mount to adjust for excessive negative camber.
Notes: Defining "standard" ride height is difficult on the XR4 as the springs on many
cars have already "sagged" 1/2 to 3/4 of an inch since new. In this case if the front
and rear tires are still wearing normally lowering the car another 1/4" or 1/2" (over what
it is currently) should not adversely effect tire wear.
Sport Spring Set -25mm (front & rear) XR M414M
Competition Spring Set -40mm (front & rear) XR M414C
Sport Spring Set*
Standard Height (front & rear) XR M414S
See Price List For Scorpio Spring Applications
pC Rear Camber Shim Kit -XR4
To correct rear camber angles on cars that have excessive negative camber
we offer a handy rear spindle shim kit. This kit is sometimes necessary on cars
with lowered sport springs, but can also be used to correct camber on cars with
"sagging" stock rear springs. The components (instructions and shims)
needed to space the rear bearing spindles between the brake backing plates
are supplied. This camber kit will add roughly 1.5 degrees of positive camber
and adjust rear toe back with in standard range as well.M423R
pD
Front Strut Tower Brace -XR4
The XR4 has a well built chassis structure that does not exhibit much flex
under normal conditions. With the addition of high performance tires and
suspension parts more stress is put on the front strut towers causing some
deflection under hard cornering which will eventually weaken the structure
and lead to unpredictable handling characteristics. Connecting the front strut
towers by adding a upper stressbar (strut tie bar) will improve chassis
stiffness and keep the suspension angles constant under hard use condi-
tions. For this purpose we offer a lightweight aluminum front tower brace
(stressbar) that incorporates a removable tubular cross brace and cast alloy
turret mounts. Highly recommended for cars that are used for track events,
drivers schools, auto-cross and spirited road use.M403F
pE
Rear Shock Mount Brace XR4
Our rear (stressbar) is a nicely finished lightweight tubular aluminum rear
brace which is just the thing for linking left and right hand upper shock mounts.
A slight bit of plastic trimming is required when fitting. Bars are supplied with
an attractive blue finish.M403R

(less expensive steel version of above) M403RS pA
Suspension Packs
0 3
pB Sport Spring Sets

pA Sway Bar Bushings H.D. Urethane sway bar bushings in 25mm for
standard XR4 and 28mm for larger Sierra Cosworth or Scorpio sway bars.
Note: XR4Ti and Scorpio sway bar clamps differ slightly making the bushings
non-interchangeable. XR's that require replacement bar clamps (see below) will
then require Scorpio type bushings to match. (bushings sold each)
Bar Bushing H.D. 25mm- (direct fit) XR4 M407BU
Bar Bushing H.D. 28mm- (direct fit) XR4 M407BAU
Bar Bushing H.D. 25mm- (special) XR4 with G407C clampG407BA
Bar Bushing H.D. 28mm- (direct fit) Scorpio G407BAU
pB
Sway Bar Bushing Clamps The European type sway bar bushing
clamp (used on Scorpio & Cosworth) has a groove to receive a ridge back
type bushing. Clamps are a direct replacement for Scorpio and can also be
used to replace worn or broken clamps on XR4 with correct bushings (see
above).
(2) required- sold each
Sway Bar Bushing Clamp (each)- Scorpio G407C
pC
Steering Rack Complete ZF type rack assemblies include inner tie
rods, boots, and stainless steel inner sleeve.
Steering Rack Assembly- XR4 M434SR
Steering Rack Assembly- Scorpio G434SR
Steering Rack Bushing Standard and H.D. (urethane) rack bushings
(2) required (sold each)
Steering Rack Bushing (each)- XR4 & Scorpio M434B
Steering Rack Bushing H.D (each)- XR4 & Scorpio M434BH
pD
Inner Tie Rod High quality European Ford inner tie rods available
for XR4 and Scorpio.
(sold each)
Inner Tie Rod- XR4Ti M434TK
Inner Tie Rod- Scorpio (left & right same) G434TK
pE
Rack Boot All rubber steering rack bellows (boots). Suitable for both
XR4 and Scorpio.
(left & right rack boots same- sold each)
Steering Rack Boot (each) -XR4 & Scorpio M434RB
pF Outer Tie Rod End High quality European Ford outer tie rod ends
available for XR4 and Scorpio.
(each)
Tie Rod End- XR4 (left) M434L
Tie Rod End- XR4 (right) M434R
Tie Rod End- Scorpio (left & right same) G434
pG
Power Steering Pumps Direct fit, replacement power steering
pumps for XR4 and Scorpio applications.
(core charge required)
Power Steering Pump- XR4Ti (integral reservoir type) M434P
Power Steering Pump- XR4Ti (remote reservoir type) M434PA
Power Steering Pump- Scorpio (all) G434P
pH
P/S Pressure Hose We have these hard to find pressure side hoses
available for all model year XR4Ti's.
P/S Pressure Hose- XR4Ti (all years) M434PH
pI
Strut Boot/Bump Stop These H.D. strut boot/bump stops help
reduce the chance of strut damage due to over-compression and/or strut rod/
seal damage from dirt and corrosion. A specially designed one piece bellows
with integral (NBR),"nitrile butadiene", variable rate bump rubber make these
especially well suited for lowered ride height suspensions.
(sold each)
Strut Boot/Bump Stop (each) -XR4 & Scorpio M405B
Front Strut Rotating Bearings
Upper Rotating Bearing (each) -Scorpio G403
Upper Rotating Bearing (each) -XR4M403
pF pC
pEpD
Suspension & Steering
pA/B
0 4
pI
pH pG

Suspension Bushing Guide
FRONT BUSHINGS XR4Ti
p pp p
pA Bushing* H.D. Upper Strut Mount (GPN)M404 24.00
*bushing (1) refits 1 strut- 2 required per car
p pp p
pB Bushings* Standard Rubber Outer TCA M428B 20.00
*bushings pair (2) refits 1 arm - "castelated" type bush
p pp p
pB Bushing Set* H.D. Rubber (GPN) M428BK-N 50.00
*includes bushings, sleeves, washers & nuts- full car set left & right
p pp p
pB Bushing Set* H.D. Urethane Outer TCA M428BK 70.00
*includes bushings & sleeves - full car set left & right
p pp p
pC Bushing* Standard Inner TCA C428 9.50
*bushing each (1) refits 1 arm - 2 required per car
p pp p
pC Bushing* H.D. (GPN) Inner TCA M428BH-N 16.75
*bushing each (1) refits 1 arm - 2 required per car
p pp p
pC Bushing Set* H.D. Urethane Inner TCAM428BU 30.00
*includes bushings & sleeves- full car set left & right
p pp p
pD Bushing* Steering Rack Standard M434B 8.70
*bushing each (1) refits 1 mounting point- 2 required per rack
p pp p
pD Bushing Set* H.D. Urethane Steeing RackM434BH 30.00
*includes bushings, sleeves- full rack set left & right
p pp p
pE Bushing* Urethane Sway Bar 25mm M407BU 20.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
note: these bushings are direct fit for XR4 bushing clamps
p pp p
pE Bushing* Urethane Sway Bar 28mm M407BAU 20.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
for use only with larger Cosworth 28mm sway bar.
note: these bushings are direct fit for XR4 bushing clamps
REAR BUSHINGS XR4Ti
p pp p
pF Bushing* H.D. (GPN) Body Beam Mount M429B 36.75
*bushing each (1) 2 required per car
p pp p
pF Bushing* H.D. Urethane Body Beam MountM429BU 54.50
*bushing with sleeve each (1) 2 required per car
p pp p
pG Bushing* H.D. Urethane Inner TCA M424BI 29.75
*bushing with sleeve each (1) refits 1 arm - 2 required per car
p pp p
pH Bushing* H.D. Urethane Outer TCA M424BO 29.75
*bushing with sleeve each (1) refits 1 arm - 2 required per car
p pp p
pI Bushing* Urethane Rear Sway Bar 12MM M408BU 6.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
for use only with standard XR4 12mm sway bar.
p pp p
pI Bushing* Urethane Rear Sway Bar 16MMM408BAU6.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
for use only with larger Cosworth 16mm sway bar.
SWAY BAR
STEERING
RACKp pp p
pA
p pp p
pBp pp p
pCp pp p
pD
p pp p
pE
FRONT SUSPENSION
CONTROL ARM
p pp p
pF
p pp p
pGp pp p
pH
p pp p
pI
REAR (TRAILING)
CONTROL ARM
SWAY BAR
REAR SUSPENSION
REAR
AXLE
Standard Rubber Bushings - Stock O.E. replacement
Hard Rubber (GPN) Bushings - Similar to standard bushing
but made with higher durometer rubber, stock appearance.
H.D. Urethane Bushings - High durometer moulded urethane
product, superior quality, low noise, easy installation.
FRONT BUSHINGS SCORPIO
p pp p
pA Bushing* Standard Upper Strut MountG404 24.90
*bushing (1) refits 1 strut- 2 required per car
p pp p
pB Bushings* Standard Rubber Outer TCA M428B 20.00
*bushings pair (2) refits 1 arm - "castelated" type bush
p pp p
pB Bushing Set* H.D. Rubber (GPN) M428BK-N 50.00
*includes bushings, sleeves, washers & nuts- full car set left & right
p pp p
pB Bushing Set* H.D. Urethane Outer TCA M428BK 70.00
*includes bushings, sleeves & nuts- full car set left & right
p pp p
pC Bushing* Standard Inner TCA G428B 12.20
*bushing each (1) refits 1 arm - 2 required per car
p pp p
pC Bushing* H.D. (GPN) Inner TCA G428H-N 22.50
*bushing each (1) refits 1 arm - 2 required per car
p pp p
pC Bushing Set* H.D. Urethane Inner TCAG428BU 35.00
*includes bushings & sleeves- full car set left & right
p pp p
pD Bushing* Steering Rack Standard M434B 8.70
*bushing each (1) refits 1 mounting point- 2 required per rack
p pp p
pD Bushing Set* H.D. Urethane Steeing RackM434BH 30.00
*includes bushings, sleeves- full rack set left & right
p pp p
pE Bushing* Urethane Sway Bar 28mm G407BAU 20.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
note: these bushings are direct fit for Scorpio bushing clamps only
REAR BUSHINGS SCORPIO
p pp p
pF Bushing* H.D. (GPN) Body Beam Mount M429B 36.75
*bushing each (1) 2 required per car
p pp p
pG Bushing* H.D. Urethane Body Beam MountM429BU54.50
*bushing with sleeve each (1) 2 required per car
p pp p
pH Bushing* H.D. Urethane Inner TCA M424BI 29.75
*bushing with sleeve each (1) refits 1 arm - 2 required per car
p pp p
pI Bushing* H.D. Urethane Outer TCA M424BO 29.75
*bushing with sleeve each (1) refits 1 arm - 2 required per car
p pp p
pI Bushing* Urethane Rear Sway Bar 16MMG408BU6.00
*bushing each (1) refits 1 mounting point- 2 required per sway bar
note: these bushings are direct fit for Scorpio bushing clamps only
0 5

pA
pC
pDpG
pH
pE
pI
pF
GAS SHOCK ABSORBERS
pA Rear Sway Bar The larger Cosworth Sierra 16mm rear
sway bar is a direct replacement for standard U.S. spec. rear
bar.
(bar includes urethane bar clamp bushings)M408
Cosworth Bar 18mm w/bush for Scorpio G408
Rear Sway Bar Shackle Worn sway bar end link shackles
can reduce the rollbars effectiveness and should be
inspected and replaced if needed. (each)M408S
Rear Sway Bar Shackle for Scorpio G408S
pB
Rear Bar Bushings H.D. urethane bushings for either
standard 12mm or Cosworth 16mm bars. (sold each)
(12mm size) M408BU (16mm size) M408BAU
pC Spring Sets See page 3 for spring selection.
pD Rear Wishbone Set H.D. Race prepared rear arms are
fully strengthened with bracing tubes and capped to give a smooth
lower surface. The shock absorber mounts are gusseted for added
reliability. Inner and outer bushings are replaced with race quality
spherical bearings. Wishbones are supplied in a durable shot
blasted, powder coated finish.
M424
pE
Outer Rear Arm Bushing H.D. Made from specalized
aircraft urethane, these heavy duty bushings offer the desired
firming effect while retaining a reasonable degree of shock and
vibration absorption. (each-
2 halves w/sleeve) M424BO
pF
Body Beam Mount Bushing H.D. This heavy duty
rubber (GP N) bushing/mounts will reduce the for/aft movement
at the rear axle beam mounting points and really does a great job
in firming up the rear end. (each)M429B
optional urethane version of above bushingM429BU
note M429BU is specially designed for easy installation
pG Inner Rear Arm Bushing H.D. Made from specalized
aircraft urethane, these heavy duty bushings offer the desired
firming effect while retaining a reasonable degree of shock and
vibration absorption. (each-
2 halves w/sleeve) M424BI
Shock Absorbers
GAS SHOCK ABSORBERSSUPERpB
Differential Mount
See Page 32
pH Complete Beam Assembly H.D. Fully race
prepared beam/subframe assembly has capped and
braced tubes and double skinned wishbone and
differential mounting plates, supplied in a durable shot
blasted, powder coated finish.M429
pI
Rear Shock Absorbers (see below - sold as each)
Spax TA series shocks utilize a non pressurized gas over oil
design with external adjustment valve (external screw in bottom)
for fine tuning the dampening to suit individual applications.
Spax is England's largest and best known manufacturer of
performance shock absorbers.M402A
Spax Sport One of the most popular shocks we sell, Spax fixed
rate gas sport shocks are an excellent choice for upgrading the
handling performance on the XR.M402V
Bilstein New for 2000. Bilstein's new sprint series gas shocks
offer the big B's renowned German made performance at a
very attractive price. Bilstein shocks are now available in our
suspension kits see page 3 for details.M402B
Rally Sport Super-Gas made to European Ford spec. by Koni
of Holland. R/S shocks feature mono-tube high pressure design and
have 4 adjustable rebound (STD., +20%, +50%, +100%) settings
which can be tailored to suit individual applications.
M402RS
Boge Turbo-Gas shocks are a German manufactured twin
tube high pressure gas design utilizing a unique variable
valving system that insures the perfect balance between
ride comfort and road holding capability.M402S
DeCarbon French made mono tube high pressure gas shocks
with fairly sporty valving, similar in design to Bilstein. M402G
KYB Gas-Adjust shocks are well made, heavy duty
dampeners that are the least expensive performance shock
upgrade for the XR4. Handling is improved without
sacrificing ride quality.M402Y
NEW
0 6Suspension (rear)
check price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items

pA Front Caliper We offer high quality re-manufactured
front calipers which are considerably less costly than new.
Calipers are handed left & right and require return core charge.
(drivers- left) M420CL(passenger- right) M420CR
pB
Caliper Repair Kit -w/piston Ford caliper repair kits are
an economical way to service a leaking or "sticky" caliper. Fitting
this kit, after honing the piston bore, will cure most caliper related
problems. (kit does 1 caliper)M420K4A
pC
Caliper Seal Kit After inspection many calipers only
require new seals to put them right. (kit does 1 caliper) M420K4
pD
Performance Street Brake Pad Set Premium
Mintex A/F series brake pads will give enhanced brake perform
over a wide temperature range with very little brake dusting.
Mintex pads also incorporate the pad warning sensor wiring.
This is the abusolute best performing street pad we have tested
and for the price they are a steal.
(XR4 & Scorpio)M420M
pD
Racing Brake Pad Sets Mintex 1144 is a rally/race pad
that is perfectly at home on track or street, offering a high coefficient
of drag (.44) and excellent modulation throughout a very wide
operating range (up to 1200 degrees). Mintex 1144 is supplied pre-
burnished for easy break-in and minimal fade on the first heating
cycle. Both fade resistance and wear characteristics are excellent.
Mintex pads are the only racing brake pads to incorporate the
standard "low pad" sensor wiring. Match a set of these pads with our
drilled or grooved sport rotors and Aeroquip stainless brake lines for
a substantial increase in braking performance.
(XR4 & Scorpio)
Mintex Street/Competition (M1144)M420G
Mintex Full Competition (M1155) M420GA
pE Standard Front Rotors Lesser quality generic "white
box" rotors tend to warp easily, don't even consider fitting them
on your XR4 or Scorpio. BAT supplies only the highest quality
(Brembo -
Italy & United Brake -England) rotors at better than
"bargain" rotor prices. (each)
XR4 M425
Scorpio G425
pE
pC
pD
pD
pA
pB pF
Brake System (front)
pH
See price list for caliper
slide bushings and pins
pG
0 7
check price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items
pF Cross Drilled Front Rotors Cross-drilling brake
rotors is an excellent way to increase brake performance.
Theory being that centrifugal force will draw excess brake
dust and expelled gasses from the pad surface through the
drilled passages into the rotors vented cavity and out. This
process also improves rotor cooling giving improved braking
response and resistance to fade. Our drilled brake rotors
are made from Carballoy (a medium flake graphite fully
pearlitic low phosphorous iron) manufactured to BS 1452
- 1990 grade 180/220 standard. The cross drilling process
is handled by computer CNC milling equipment with holes
arranged in a parabolic pattern giving an even sweeping
effect to the pad surface ensuring maximum cooling with
minimum noise and drag. M425CD
*rotors must by purchased as (handed) pairs- priced as each
Grooved Front Rotors As an option we can supply
slotted (grooved) pattern rotors which are manufactured to
the same high standards as the above listed cross drilled
versions.M425S
*rotors must by purchased as (handed) pairs- priced as each
Drilled & Slotted Front Rotors As an option we can
supply combination drilled & slotted (grooved) pattern
r o t o r s manufactured to the same high standards as the above
listed cross drilled versions.M425CDS
*rotors must by purchased as (handed) pairs- priced as each
pG Master Cylinder high quality Bendix replacement power
brake master cylinder.
(specify year when ordering)M420MC
pH
Aeroquip Brake Lines One of the more effective brake
modifications you can make is to replace the standard brake
hoses with Aeroquip steel braided lines. These performance
brake hoses incorporate a teflon interior to keep line expansion
"flexing" to a minimum. This greatly reduces the "spongy" pedal
feel common to the XR4 & Scorpio brake system. Our stainless
lines are assembled from genuine Aeroquip AN-3 hose with
premium metric "reusable" (not the lesser quality "swaged" type)
hose ends installed. XR4Ti (state year) M419
Scorpio G419

pC
pDpBpA
pA Front Brake Special 260 x 24mm
This kit is just the thing for replacing the standard size, wear related,
front brake components. We supply high quality Euro specification
rotors and premium Mintex brake pads for either XR4 or Scorpio and
at a special price as compared to buying items separately.
Front Brake Special XR4ti M420SP
Front Brake Special Scorpio G420SP
pB
BAT R/S Front Brake Kit (283 x 24mm) XR4ti
BAT R/S Brake Kit allows larger 11.25" (283mm) Cosworth brake
rotors to be fitted with standard XR calipers. Increasing rotor "swept
area" in this way will greatly improve stopping power (leverage) and
help to reduce high brake temperatures that can cause premature
brake fade and poor pedal feel. Kits are available in 4 different
component levels from as little as $295.00, which leaves you no
reason not to upgrade to larger brakes.
Kits include: 285 x 24mm
vented (standard or cross-drilled) rotors, Mintex brake pad set
(standard or M1144), caliper mounting brackets & hardware (fitment
with most 15" and larger wheels -some require modification or
spacers)
Front R/S Brake Kit (283 x 24mm) M417
includes standard rotors, standard Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M417A
includes X-drilled rotors, standard Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M418
includes standard rotors, M1144 Mintex pads, brackets & hardware
Front R/S Brake Kit (283 x 24mm) M418A
includes X-drilled rotors, M1144 Mintex pads, brackets & hardware
pC BAT/Wilwood Front Brake Kit (283 x 24mm) XR4ti
This kit combines the performance of the larger 283mm Cosworth rotor
with Wilwood 4 piston Superlite 2A calipers which are extremely ridged
and transfer torque directly without unwanted flex. Construction is
aluminum with stainless pistons for both weight savings and maximum
head dissipation. At just 5 lbs. they are also much lighter than stock
calipers. This goes a long way to reducing "unsprung" weight benefiting
both braking and handling performance.
Kit includes: 285 x 24mm
vented rotors, 4-piston alloy Wilwood Superlite IIA calipers with pads
and aeroquip brake hoses (fitment with most 15" and larger wheels -
some require modification or spacers)
M416W
pD
BAT/Wilwood Front Brake Kit (300 x 24mm) XR4ti
This kit combines even larger 300mm Cosworth rotor with Wilwood
4 piston Billet Dynalite for the ultimate big brake kit. Calipers are
extremely ridged and transfer torque directly without unwanted
flex and are made from aluminum with stainless pistons for both
weight savings and maximum head dissipation. At just 4 lbs. they
are also much lighter than stock calipers. This goes a long way to
reducing "unsprung" weight benefiting both braking and handling
performance.
Kit includes: 300 x 24mm vented rotors , 4-piston
alloy Wilwood Billet Dynalite calipers with pads and aeroquip
brake hoses (fitment with some 15" & most 16" and larger wheels
-some require modification or spacers)
M416W3
Brake Kits & Specials0 8

pA
pBpC
pEpD
pE Rear Brake Parts Kit This handy kit includes all of the
small parts, springs and other attaching hardware for the rear
drum brakes. One kit does both hand sides.M420K5
Rear Brake Special Our rear brake special has all the
items (brake shoes, wheel cylinders & small parts kit)
required for a complete rear brake overhaul, and all at a very
attractive price.M420RSPL
pF
Rear Disk Brake Kit Converting to rear disk brakes
could not be any easier than with our ventilated rear disk
conversion kit. Not only will braking performance be greatly
improved but servicing the friction material (pads) becomes a
much easier task than messing with the old shoes. Kit incudes:
calipers & mounting plates, vented 260mm rotors, brake lines,
hand brake cables, and assorted hardware.M420RK
Note: see price list for individual listings on service parts for
above rear disk brake kit.
XR4 & Scorpio Hand Brake Cables We have replacement
hand brake cable assemblies for both the XR4Ti and Scorpio.
These have been recently discontinued by Ford USA.
Hand Brake Cable XR4Ti M564
Handbrake Cable Scorpio G564
Cosworth Hand Brake Cable required for fitting a
Cosworth rear brake conversion to the XR4 or servicing cars
with existing Cosworth rear brake cables.Z16567
Scorpio Rear Brake Components BAT also stocks
brake components for servicing and upgrading the rear
brakes on the Merkur Scorpio.
Rear Rotor (standard) G425R
Rear Rotor (cross drilled) G425RCD
Rear Caliper (left or right) G420RL/RR
Rear Pad Set G420R pA
Rear Wheel Cylinder Backing plates should be checked
periodically for brake fluid drips or a damp spot at the bottom (a sure
sign of a leaky wheel cylinder). We recommend (and sell) only new
replacement wheel cylinders because of the high incidence of
failure found with re-manufactured units.M420WC
pB Rear Brake Shoes Our premium quality rear brake shoes
are supplied as either European Motorcraft or Mintex brand. Both
are new (non re-manufactured) high quality semi-metallic
replacement linings, not the typical "white box specials".
Note:
fitting reman rear shoes can be a problem as most we have seen
have thicker than standard bonded linings making it difficult, if not
impossible, to reinstall the drum.
M420R
pC
Rear Brake Drum Brake drums that are warped or
beyond minium specification for wear should be replaced.
New rear brake drums are sold each.M420RD
pC
Rear Brake Drum (Grooved) These rear drums offer
an extra degree of braking performance not found when
using standard rear drums. Drums have 12 spiral grooves
for maximum cooling and deglazing effect. Grooved drums
are sold in handed pairs.M420RDG
pD
Aeroquip Rear Brake Lines One of the more effective
brake modifications you can make to the XR4 & Scorpio is to
replace the standard brake hoses with Aeroquip steel braided lines.
These performance brake hoses incorporate a teflon interior to
keep line expansion "flexing" to a minimum. This greatly reduces
the "spongy" pedal feel common to most brake systems. Our
stainless lines are assembled from genuine Aeroquip AN-3 hose
with premium metric "reusable" (not the lesser quality "swaged"
type) hose ends installed.
XR4 Rear Aeroquip Brake Line Set M419R
Scorpio Rear Aeroquip Brake Line Set (4 lines)G419R
Brake System (rear)
check price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed itemscheck price lists for Scorpio versions of listed items check price lists for Scorpio versions of listed items
check price lists for Scorpio versions of listed items
pF
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