automatic transmission FORD SIERRA 1990 2.G XR4 Workshop Manual

pA Constant Velocity Joints & Boots The Merkur XR4Ti and Scorpio
independent rear axle assemblys utilize half shafts that have inner and outer constant
velocity joints. Eventually these joints and protective boots will require service. We
have joints and boots available separately making it economical to replace just the
worn component without having to replace whole axle assembly. However, if more
than one C.V. per axle requires service, our complete axle assembly is the more cost
effictive way to go.
Note: right/left inboard and outboard C.V. joints and boots are
interchangeable- see price list for complete axle prices (handed left & right)
Constant Velocity Joint- XR4 & ScorpioM550B
C.V. Boot Kit-
XR4 & ScorpioM550BK
Complete Axle(specify left or right)-
XR4 & ScorpioM550L/R
pB
Rubber Drive Shaft Coupling The rubber "Drive Donut" or "Rotoflex
Coupling" on the XR4 and Scorpio drive shaft can be a real bugger. Many owners
have contacted us after being quoted up to 500.00 to totally replace the complete
drive shaft assembly by the local Ford L/M dealer, as they do NOT list the rubber
drive coupling as a separate service part. We import the proper replacement
drive coupling and make it available at considerable savings to you. If your car
exhibits a driveline shudder that increases with speed, (especially noticeable in
colder weather) we recommend taking a close look at the condition of the drive
coupling. Cracks in the rubber or missing pieces will require immediate replace-
ment, loosing one of these joints at speed will be very messy !
Note: BAT supplies
the standard equipment XR4i drive coupling by the original supplier to Ford. This
is not a lesser "fits all" component that just happens to be similar.
Rubber Drive Shaft Coupling- XR4 & ScorpioM17A
pC
Drive Shaft Center Support Bearing- Replacement driveshaft
center support bearing assemblys for XR4Ti and Scorpio.
Drive Shaft Center Support Bearing- XR4Ti M550SB
Drive Shaft Center Support Bearing- Scorpio G550SB
pD
Quaife Torque Biasing Differential Quaife torque biasing
differentials provide a constant and infinitely variable output to both rear
wheels. These unique differentials utilize a series of helical gears which
sense the amount of applied torque and adjust automatically for loss of
traction. The Quaife limited slip design is also free of high wear items
(clutches, ratchets and plates), making them stronger and more maintenance
free than other types of limited slip units. Anyone who has had the pleasure
of driving a vehicle equipped with a Quaife LSD will immediately comment on
its smooth seamless performance, very unlike clutch/plate type LSD's which
exhibit a notchy ratchet like take up through the drive line. The Quaife LSD
that we offer is originally designed as a replacement upgrade for the Sierra
Cosworth and are now supplied with output flanges tapped for either the large
108mm (Cosworth size) or smaller 100mm (XR4 size) C.V. joints.
Quaife Limited Slip DifferentialM710
pE
Clutch Kits We have a very good selection of clutch packages that include
clutch disk, pressure plate, throw out bearing, and clutch alignment tools. Buying one
of our engineered kits will guarantee best quality, performance, fitment (ease of
installation) and price. First option is a new (not rebuilt or re-lined) O.E. quality
replacement clutch kit by Sachs/Valeo. This clutch is best suited for standard or
slightly modified cars being used under normal driving conditions. If your requirements
are beyond the capabilities of the standard clutch we also have some heavy duty clutch
kit options. H.D. clutch kits include pressure plates that have increased clamping force
(from 30 to 50%) and clutch disks with high temperature friction materials applied.
Centerforce H.D. clutch kits have a unique centrifugal pressure plate design with
substantially more clamping force but requires very little pedal pressure over the stock
clutch.
Note: all kits are for standard transmission 1" 23 spline except where noted.
Sachs Clutch Kit XR - best quality O.E. clutchM519K
Sachs Clutch Kit Scorpio -
best quality O.E. clutchG519K
Sachs Clutch Kit XR w/ T5 Trans -
1 1/16" 10 spline for T-5 transM519T5
H.D. Centerforce Clutch Kit -
uprated disk & 30% p. plateM519C
H.D. Center Force II Clutch Kit -
uprated disk & 50% p. plateM519C2
Clutch Alignment Tool -
1" 23 spline for std. transmissionS11H
Clutch Cable- XR4Ti M562
Clutch Cable- Scorpio G562pD
Driveline
pA
pD pB
pC
1 1

Engine & Related Items
2.5mm metallic inductance EMI
suppressed conductor: with
stainless steel windings spaced
over ferrimagnetic core
substrate
serves as
strength
member for
cable assembly
ignition cables have a non-layered high strenght insulating
jacket made entirely of aerospace grade silicone rubber to
prevent swelling and splitting at extreme trmperatures
KV85 & R-100
metallic inductance EMI
suppressed conductor
pA Performance Air Filters A quick and easy performance modification
is to replace the standard air filter with a direct fit KN high performance air filter.
Merkur XR4Ti (2.3L Turbo)M22P
Merkur Scorpio (2.9L V-6)G22P
pB
High Temp Fyre Sleeve The under hood temperatures on the XR4Ti can
be quite severe. Slipping a length of fyre sleeve over critical wiring or rubber water
& A/C hoses will add an extra degree of protection. Fyre Sleeve provides radiant heat
protection up to 800 degrees. Sleeve is sold per foot and is sized by internal diameter.
Hoses or wiring can be disconnected at one or both ends then slipped through fyre
sleeve or sleeve can be un-stitched at the seam and wire tied in place.
Mylar Fyre Foil Sleeve -10 (7/8" I.D.) per foot320510
Mylar Fyre Foil Sleeve -12 (1" I.D.) per foot320512
Mylar Fyre Foil Sleeve -16 (1 1/4" I.D.) per foot320516
Mylar Fyre Foil Sleeve -20 (1 1/2" I.D.) per foot320520
pC
Engine Mount Insulators BAT has an alternative to the recently
discontinued original equipment Ford motor mounts on the XR4Ti. Simply
remove the old motor mount assemblies, discard the worn-out rubber
portion, and reuse the top and bottom metal plates with our replacement
insulators.
Note: slight modification requires 10mm holes in plates to be
increased to 12mm. Scorpio mounts are Ford mfg. direct replacements.
Engine Mount Insulator (left & right same) XR4TiM433
Engine Mount Insulator (left & right same) Scorpio-
new FordG433
pD
Transmission Mount /Insulator Rear transmission mount/insulator-
direct fit for automatic & manual Scorpio. A heavy duty version also available.
Note:
this "square" type mount can be fitted to the XR4 with special crossmember, (see
below) as the standard "round" trans. mount used on our XR4Ti's is no longer available.
Transmission Mount Insulator*- (automatic & manual) G433T
Transmission Mount Insulator H.D*.- (automatic & manual) M433TA
*can be fitted to XR4 with additional x-member (see below)
pE Transmission Crossmember Wide and narrow type transmission
tunnel crossmenbers allow the above "square" mount/insulators to be installed in
the XR4Ti. Fitting the XR with this crossmember/mount combination is a consider-
able upgrade (strength, noise, vibration) over the USA supplied "round" mount.
Crossmember* XR4 (wide) 1987-89- manual & auto M433XL
Crossmember* XR4 (narrow) 1985-86- manual & autoM433X
*for use in combination with above G433, M433 "square" type mount
pF Engine Belts H.D. Our search for the ultimate heavy duty engine
accessory v-belts lead us to the top cog "Gold Series" by Dayco. Top cog v-
belts are built to last up to 20% longer than conventional belts. A unique cogged
design increases flexibility and airflow around the belt for reduced friction and
heat. Laminated design with high temperature rated polyester cords provide
maximum tension holding (reduced slip) over the life of the belt.
Belt- XR4Ti (1985-89) W. Pump, Alt, P. Steering (2 required)M6G
Belt- XR4Ti (1986-89) A/C CompressorM6H
Belt- XR4Ti (1985) A/C CompressorM6HA
Belt- Scorpio (1988-89) Fan & Power Steering (2 required)G6G
Belt- Scorpio (1988-89) AlternatorG6GA
Belt- Scorpio (1988-89) A/C CompressorG6H
pG
Performance Ignition Wire Sets We have tried a number of
different ignition wire options on the 2.3 Turbo and 2.9L V6 engines and have
found the Magnecor brand to offer superior quality, performance, and durability.
Cables are red in color with 8mm, 8.5mm and 10mm cable diameters.
Merkur XR4Ti (2.3L Turbo)
Ignition Wire Set- (8mm w/silicone jacket and boots)L9HT
Ignition Wire Set- (8.5mm KV85 wire w/silicone jacket and boots)M9HT
Ignition Wire Set- (10mm R-100 wire w/silicone jacket and boots)M9HTR
Merkur Scorpio (2.9L V6)
Ignition Wire Set- (8mm w/silicone jacket and boots)G9HT
Ignition Wire Set- (8.5mm KV85 wire w/silicone jacket and boots)G9HT9 pG
pF
pA
Aluminized Mylar Fyre Sleeve
pB
pC pD
pE
2 7

ABEFG
HIFJK
L
N
O
YZ
GG
The Ford Type 9 (T9) or Hummer transmission is a 5-speed version/
conversion (an overdrive portion is added in a casting extension
behind the main case) of the venerable Type E 4-speed. The only
problem with this transmission is the 2.3 turbo engine's torque output
is near the top of T9's performance envelope. It would seem that
Ford's choice of manual and automatic transmissions were both
marginal at best for use in the XR4Ti. Even so the T9 can give better
than average service when driven sensibly. However, they do not
fair well when abused! A sure sign of problems is a "growling" input
shaft bearing. The sooner this is attended to the better. When the
input bearing fails it will take with it some, or all, of the gearing making
for an expensive repair bill. We can supply individual T9 replacement
parts from this list as requested.pNSyncronizer Ring- 1st/2nd gear M711$33.25
pO
Blocker Spring- syncronizer Z61547.55c
pP
Mainshaft w/Reverse- mainshaft w/reverse gear$308.25
pQ
Gear- 1st gear $172.79
pR
Spacer- oil scoop ring $3.50
pS
Bearing- shaft roller bearing M705$38.35
pT
Circlip- specify thickness size below$4.05
2.42, 2.48, 2.54, 2.61, 2.67mm
pU
Snap Ring- specify size below M705A.85c
1.75, 1.81, 1.87, 1.93, 1.99mm
pV
Gear- 5th driven gear $214.00
pW
Spacer- oil scoop ring $1.20
pX
Blocker Spring- syncronizer Z60785.69c
pY
Syncro Hub- 5th gear syncro hub assembly $129.50
pZ
Syncronizer Ring- 5th gear M713$26.15
pAA
Syncronizer Hub- 5th gear syncro hub $129.50
pBB
Bearing- roller bearing (1987 and up) M707$18.10
pBB
Bearing- 19mm needle (85-87) 21 required M707N$1.89
Spacer/Washer- (1985-87) 2 to 4 required M707S$1.50
pCCGear Cluster- countershaft gear cluster $379.65
pDD
Bearing- roller ball bearing M706$34.50
pEE
Circlip- specify thickness size below$2.00
1.88, 1.95, 2.12, 2.19, 2.25mm
pFF
Gear- 5th driver gear $184.25
pGG
Nut- countershaft nut (12 sided) M706N$4.35
pHH
Countershaft- shaft only Z61892$60.50
pI I
Gear- reverse idler gear $153.20
pJJ
Bushing- reverse idler bush $5.00
pKKIdler Shaft- shaft for reverse idler gear $30.50
FF
KK
JJ
II DD
EE
DD UVWAA
*see page 26 for transmission gaskets & seals
CC
HH Q
N
BBOPU
(early)
87> roller bearing assembly (1 piece)
(late)
G
D
C
M
RSTXX
pASnap Ring- front input shaft (large) M701$2.00
pB
Circlip- front input shaft (small) M701A$2.00
specify size 2.16, 2.24, 2.33, 2.42, 2.50mm
pC
Bearing- input shaft roller bearing M702$29.50
pD
Input Shaft- for XR4Ti $255.00
for Scorpio $220.75
pE
Bearing- rear input needle cage M704$7.15
pF
Syncronizer Ring- 3rd/4th gear syncro M712$26.15
pG
Blocker Spring- syncronizer Z60784.35c
pH
Snap Ring- specify size below M704A$2.00
1.63, 1.74, 1.85mm
pI
Syncronizer Assembly- 3rd/4th gear syncro unit $226.30
pJ
Gear- 3rd gear $149.30
pK
Thrust Ring- retainer 3rd gear $2.00
pLThrust Washer- thrust washer 1/2 Z61144$2.72ea.
pMGear- 2rd gear $155.00
Transmission Components3 3