air suspension FORD SIERRA 1983 1.G XR4 Workshop Manual

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 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

Accessories (books)
pA The Sporting Fords- Volume 4: Sierras by Graham Robson.
This book has comprehensive information on the development and
history of all Sierra, Sierra Cosworth, and Merkur models. Chapters
include production street and race versions of the cars, technical
information and specifications, buyers and identification guide,
performance figures and much more.
Hard bound 9 1/2" x 7 1/2", 128
pages, 131 black & white illustrations.
M207
pB High Performance Sierras & Merkurs by various authors.
Packed with reprints of magazine articles, road tests of production
and racing cars, data & comparisons, development, specifications,
and tuning. Cars covered in this publication are Sierra, Sierra
Cosworth, RS500, XR 4x4, and Merkur XR4Ti models.
Soft bound 8
1/2" x 11", 172 pages, 200 + black & white illustrations.
M206
pC Classics in Color - Ford Sierra Cosworth by Dennis Foy &
Terry West. A full color profile of the Sierra Cosworth line
including R/S Cosworth, RS500, Cosworth 4x4, and Cosworth
Sapphire. Great color photographs of both production and racing
variants of these unique vehicles.
Soft bound 7 1/2" x 10, 96
pages, 130 color illustrations.
M203
pD Workshop Manual- Sierra 1982-1992 by Haynes. Covers the
European Sierra & Sapphire 4 cylinder models (except Cosworth). Lots
of good information covering repair procedures (light-years ahead of
Chiltons). Most sections, with the exception of the engine, are the same
or similar to the US cars. An inexpensive alternative or addition to the
American Merkur Manual.
Hard bound 8 1/2" x 11 ", 250 pagesM204
pE Workshop Manual- Sierra XR4i (V6) by Haynes. Similar to
above, covers the XR4i & XR4x4 V6 equipped models.
Hard bound
8 1/2" x 11 ", 250 pages
M204A
pF Workshop Manual- Scorpio (V6) by Haynes Covers the
European Scorpio/Granada V6 models- very similar to our US spec cars.
A handy manual to have.
Hard bound 8 1/2" x 11 ", 250 pagesG204
pG Build & Modify Ford V6 Engines by Sven Pruett. A very
well done build and tune book covering the V6 Ford 2.6, 2.8, 2.9, 4.0L
engines.
Soft bound 8 1/2" x 11", 160 pages.G202
pA
pC
pB
pD
pFpE
pG
pH
pH How To Prepare The Sierra For Motorsport by Ford Motor
Company Competition Department & Graham Robson. Complete
guide to race preparing the European specification Sierra for
motorsports competition. Chapters on modifying suspension, body,
engine, driveline, brakes, clutch, and differential- including
specifications and part number listings.
Soft bound 8 1/4" x 11 3/4",
147 pages, 150 black & white illustrations.
M205
Workshop Manual- Sierra & Escort Cosworth origional European
Ford shop manuals (2 volume set) for the Cosworth cars.M202
The Complete 2.3L Turbo EEC-IV Handbook a comprehensive
view of the engineering, performance characteristics, and troubleshooting
for each component of the EEC-IV engine control system.M209
Ford Sierra Cosworth
Dennis Foy & Terry West
(Not Pictured)
2 0

Price List
This catalog is viewable and
downloadable from our internet site
(www.batinc.net) you can get
catalog updates there too.
PAGE 2 front suspension & steering
Front Sway Bar- Cosworth 28mm M407 185.00
Front Strut- Spax Adjustable (each) XR M401A 165.00
Front Strut- Spax Sport- fixed rate- (each) XR M401V 99.50
Front Strut- Bilstein-Gas- (each) XR M401B 92.50
Front Strut- R/S Adjustable (each) XR M401RS 219.95
Front Strut- Koni Sport (each) Scorpio G401K 199.95
Front Strut- Boge Turbo-Gas (each) XR M401S 97.50
Front Strut- Boge Turbo-Gas (each) Scorpio G401S 101.50
Front Strut- DeCarbon Gas (each) XR M401G 145.00
Front Strut- DeCarbon Gas (each) Scorpio G401G 145.00
Front Strut- KYB GR2 (each) XR M401Y 99.50
Front Strut- KYB GR2 (each) Scorpio G401Y 99.50
Steering Rack Assembly* (XR) M434SR 349.00
Steering Rack Assembly* Scorpio G434SR 349.00
*this item requires an additional 100.00 charge refundable upon core return
Steering Rack Bushing H.D. (set) M434BH 30.00
Steering Rack Boot (left or right) XR & Scorpio M434RB 15.50
Control Arm* (left) XR M428L 75.00
Control Arm* (left) Scorpio G428L 99.50
Control Arm* (right) XR M428R 75.00
Control Arm* (right) Scorpio G428R 99.50
*NEW control arms (ball joints and bushings are installed)
Adjustable Control Arms (pair) w/bushings DISCONTINUED
Adjustable Control Arms- Race (pair) DISCONTINUED
Bushing- H.D. (GPN) Inner Control Arm (each) M428BH-N 16.75
Bushing- H.D. (GPN) Inner Control Arm (each) ScorpioG428BH-N 22.50
Bushings- Urethane Inner Control Arm (set) M428BU 30.00
Bushings- Urethane Inner Control Arm (set) Scoprio G428BU 35.00
Bushing (standard) Inner Control Arm (each) XR C428B 9.50
Bushings*- Urethane Outer Control/Sway (set) M428BK 70.00
Bushings*- H.D. (GPN) Outer Control/Sway (set) M428BK-N 50.00
Bushings*(standard) Outer Control/Sway (1 arm pair) M428B 20.00
*M428B, M428BK & M428BK-N are all suitable for Scorpio
Washer (shallow)- Sway Bar / Outer TCA (each) M407W 2.95
Tie Rod End (left) XR M434L 24.50
Tie Rod End (right) XR M434R 24.50
Tie Rod End (same L or R) Scorpio G434 27.50
Mount/Insulator -H.D. Upper Strut (each) XR M404 24.00
Upper Strut Mount/Insulator- Scorpio (each) G404 24.50
Upper Strut Rotating Bearing- Scorpio (each) G403 7.95
Upper Strut Rotating Bearing- XR4 (each) M403 9.50
PAGE 3 suspension components
Spax Sport Kit -XR M400S 495.00
Spax Sport Kit (adjustable) XR M400A 649.00
Sport Spring Set (4) front/rear (-25mm) XR M414M 189.50
Sport Spring Set (4) front/rear (-40mm) XR M414C 225.00
Sport Spring Set (4) front/rear (standard height) XR M414S 249.00
Sport Spring Set (4) front/rear (-30mm) Scorpio G414M 269.00
Front Spring Scorpio - Standard O.E. Ford (each) G414 63.65
Rear Spring Scorpio - Standard O.E. Ford (each) G415 106.40
Rear Camber Shim Kit -XR M423R 30.00
Front Upper Strut Brace (alloy) XR M403F 149.50
Rear Upper Shock Brace (alloy) XR M403R 142.50
Rear Upper Shock Brace (steel) XR M403RS 78.00
PAGE 4 suspension components
Bar Bushing H.D. 25mm- XR4 w/standard bar M407BU 20.00
Bar Bushing H.D. 28mm- XR4 w/Cosworth barM407BAU 20.00
Bar Bushing H.D. 25mm- XR4 w/ std. bar & G407C clampG407BA 20.00Bar Bushing H.D. 28mm- ScorpioG407BAU 20.00
Front Sway Bar Clamp- Scorpio (each) M407C 7.50
Steering Rack Assembly* XR M434SR 349.00
Steering Rack Assembly* Scorpio G434SR 349.00
*this item requires an additional 100.00 charge refundable upon core return
Steering Rack Bushing (each) M434B 8.70
Steering Rack Bushing H.D. (each) M434BH 20.00
Inner Tie Rod -XR4 M434TK 51.00
Inner Tie Rod -Scorpio G434TK 51.00Steering Rack Boot (left or right) XR & Scorpio M434RB 16.75
Outer Tie Rod End (left) XR M434L 24.50
Outer Tie Rod End (right) XR M434R 24.50
Outer Tie Rod End (same L or R) Scorpio G434 27.50
Power Steering Pump XR4Ti* (integral reservoir) M434P 135.00
Power Steering Pump XR4Ti* (remote reservoir) M434PA 136.00
Power Steering Pump Scorpio* G434P 136.00
*this item requires an additional 25.00 charge refundable upon core return
P/S Pressure Hose XR4Ti M434PH 58.33
Strut Boot/Bump Stop (each) XR & Scorpio M405B 19.00
Strut Insulator/Bearing Kit XR4 (does 1 side) M403K 7.00
Upper Rotating Bearing XR4 (each) M403 8.50
Upper Rotating Bearing Scorpio (each) G403 7.95
PAGE 5
Pricing is listed with part numbers on this pages
PAGE 6
rear suspension
Rear Sway Bar w/bush- Cosworth 16mm (XR4) M408 99.50Rear Sway Bar w/bush- Cosworth 18mm (Scorpio only)G408 89.95
Rear Bar End Shackle (each) -XR M408S 15.00
Rear Bar End Shackle (each) -Scorpio G408S 15.00
Rear Bar Bush(12mm) urethane (each) stock XR4 M408BU 6.00
Rear Bar Bush (16mm) urethane (each) Cosworth M408BAU 6.00
Rear Bar Bush (16mm) urethane (each) Scorpio G408BU 6.00
Rear Control Arm Set -H.D. Competition M424 675.00
Bushing*- Urethane Outer Control Arm (each) M424BO 29.75
Bushing*- GPN Outer Control Arm (each) M424BO-N 30.50
Bushing*- GPN Body Beam Mount (each) M429B 36.75
Bushing*- Urethane H.D. Body Beam Mount (each) M429BU 54.50
Bushing*- Urethane Inner Control Arm (each) M424BI 29.75
*above bushings also Scorpio suitable
Beam/Subframe Assembly -H.D. CompetitionDISCONTINUED
Rear Shock- Spax Adjustable (each) XR M402A 89.00
Rear Shock- Spax Adjustable (each) Scorpio G402A 105.50
Rear Shock- Spax Sport- fixed rate- (each) XR M402V 75.00
Rear Shock- Bilstein- Gas (each) XR M402B 73.00
Rear Shock- Koni R/S Adjustable (each) XR M402RS 99.50
Rear Shock- Koni Sport (each) Scorpio G402K 122.85Rear Shock- Boge Turbo-Gas (each) XR M402S 75.50
Rear Shock- Boge Turbo-Gas (each) Scorpio G402S 62.50
Rear Shock- DeCarbon-Gas (each) XR M402G 63.00Rear Shock- DeCarbon-Gas (each) Scorpio G402G 87.00
Rear Shock- KYB (each) XR M402Y 46.50
Rear Shock -KYB (each) Scorpio G402Y 46.50
IMPORTANT PRICE LIST NOTES:
(1) Scorpio versions of listed XR4 parts will generally
appear below XR4 item in
italics.
(2) Items that apply for both XR4 & Scorpio are noted.
(3) Fitment notes, and core charge information is also
italicized.
(4) Additional items that do not appear in the literature
can be found in with the corresponding category /
page number reference. These listings are also
italicized.
3 503/11/02