RON FORD SIERRA 1990 2.G XR4 Workshop Manual

pC pB
pD pJ
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pE
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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
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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
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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
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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
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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
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Tie Rod Ends High quality European Ford standard
replacement tie rod ends. (left) M434L (right) M434R
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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
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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
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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
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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
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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
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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
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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
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Suspension & Steering
pA/B
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pH pG

Suspension Bushing Guide
FRONT BUSHINGS XR4Ti
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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
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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
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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
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pBp pp p
pCp pp p
pD
p pp p
pE
FRONT SUSPENSION
CONTROL ARM
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pF
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pGp pp p
pH
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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
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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)
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See price list for caliper
slide bushings and pins
pG
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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

Brake (related)
pA
pEpA
Racing Brake Fluid Not all brake fluid is created equally. High
operating temperatures at the caliper transfers extreme heat through the piston
causing lesser quality brake fluid to boil. This in turn allows the fluid to become
compressed and reduces overall braking performance. The best way to
counter this from happening is to use a racing specification, mineral (never
synthetic) brake fluid and flush the system after each event for competition or
annually on performance street driven vehicles. Both AP550 and Wilwood 570
brake fluid is DOT approved with a dry boiling point of 550-570 degrees, low
viscosity minimizes aeration and permits easy bleeding.
Brake Fluid AP Competition (16.9oz. 500ml.) MC550
Brake Fluid Wilwood 570 (12oz. 355ml.) MC570
Brake Fluid Wilwood 570 (6 Pack) MC57-6
Brake Fluid Wilwood 570 (24 Case) MC57-C
pB
Cosworth & Scorpio Rotors For those fortunate few who own
Cosworth Sierras or have converted XR4's to Cosworth type front or rear brakes
and are in need of replacement rotors we have them. Scorpio front or rear rotors
in standard and cross drilled are also available. (see price list page 31)
Cosworth Front 283 x 24mm standard, X-drilled, grooved
Cosworth Rear 273 x 10mm standard, X-drilled, grooved
Scorpio Front 260 x 24mm standard or X-drilled
Scorpio Rear 253 x 10mm standard or X-drilled
Performance Brake Kits Engineered competition brake kits for the
ultimate in stopping power.
pC Front R/S Brake Kit (283 x 24mm)
BAT R/S "big brake" kit allows larger 11.25" (285mm) 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.
Kit includes:
285 x 24mm vented (standard or cross-drilled) rotors, Mintex 1144 brake pad
set, caliper mounting brackets & hardware (fitment with most 15" wheels -
some require slight modification)
kit supplied with standard rotors
M418
kit supplied with cross drilled rotors M418A
pD Front Brake Kit (283 x 24mm) w/4 Piston Calipers
Combine the performance of the R/S large rotor kit with 4 piston calipers for the
ultimate in stopping power.
includes: 283 x 24mm vented rotors,
4-piston alloy Wilwood Superlite 2A calipers with pads. (fitment with most 15"
wheels -some require modification or spacers)
M416W
pD Front Brake Kit (300 x 32mm) w/4 Piston Calipers
For those who are looking for the ultimate brake performance. Quite simply the
largest and most competent competition type brake kit that can be fitted to the XR4.
includes: 300 x 32mm vented rotors with light alloy hats, 4-piston alloy Wilwood
Superlite IIA calipers, caliper mounting brackets & hardware
M417A
(this kit also available for Scorpio ! ) G417A
Rear Kit (XR4 w/16" wheels) 300 x 21mm (See Price List)
includes: 300 x 21mm vented rotors with light alloy hats, 4-piston alloy Wilwood
Superlite 2A calipers, caliper mounting brackets & hardware
pE Wheel Bearings Genuine European Ford wheel bearing kits are
complete with all required service parts to do a first class job. Each kit
include bearings, races, seals and hub nuts to service one wheel.
Front Wheel Bearing Kit (specify left or right) -XR4 M560F
Rear Wheel Bearing Kit (specify left or right) -XR4 M560R
Front Wheel Bearing Kit (specify left or right) -Scorpio G560F
Rear Wheel Bearing Kit (specify left or right) -Scorpio G560R
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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
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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
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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
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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
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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
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Bodywork
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pA Front Fenders European Sierra fenders are a direct replacement for the
XR4Ti and are an attractive alternative considering the high price of the American
version. These fenders also include the holes required for side blinker mounting
(see below).
Note: specify left or right when ordering M806 L/R
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Inner Wheel Well Splash/Liners Replacements for the commonly
cracked, broken or missing inner fender splash on the XR4. Covers full inner
wheel house area as origional USA versions.
specify left or right M808L/R
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Door Skin - (specify left or right)M807 L/R
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Door Handle XR4 & Scorpio - (specify left or right)M362 L/R
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Door Sill (Rocker Panel) - (specify left or right)M803 L/R
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Rear Wheel Arch - (specify left or right)M804 L/R
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Battery TrayM817
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Rear PanelM815
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Cosworth Front Grille Nothing transforms the look of the XR4Ti quite like
adding a Cosworth grille. Designed with a center opening, the Cosworth grille
adds additional air flow to the radiator and A/C condenser for a cooler running
engine and better air conditioning performance. An intercooler could also be fitted
behind the grille opening as is done on the original Cosworth Sierra and R/S 500
models.
Note: Grilles are O.E. quality (injection moulded plastic) not shoddy fiberglass
replicas. Suppled (primed) un-painted- includes "Ford" emblem
M320
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Grille Surround Gasket This gasket will almost always need to be
replaced when fitting a new grille.M320S
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European Side Blinker Lamp Kit Add an extra degree of safety when
signaling to turn. Side blinkers fit above European fenders without modification
and can also be fitted to standard Merkur XR4Ti fenders by drilling a mounting
hole. Kit includes (2) lamps, wiring and templates.M317
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Cosworth Hood Original equipment Ford Sierra Cosworth hoods are
designed to receive hood vents/louvers for additional under hood cooling. These
hoods look quite distinctive as the raised center section is lower and wider than
on the standard XR4 hood giving the car a more aggressive appearance.M813
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Cosworth Hood Vents Hood louvers/vents are both visually striking and
functional as they help to ventilate the engine compartment. These O.E. Ford vents
(pair) bolt into the Cosworth hood (above) or can be fitted to standard hoods by cutting
a hole and bonding them in place.
(see pg 11 for fiberglass versions)M814
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Cosworth Front Spoiler/Bumper We supply everything required to
install the stunningly attractive Cosworth Sierra front spoiler/bumper to your
XR4Ti. All components are original Ford including; bumper, bumper bar
brackets, lower side fender mounting panels, fog lamps, turn signal lamps, and
assorted hardware (clips & fasteners).
Note: bumpers are supplied in white-
can be painted to match other colors.
M353
(R/S 500 Version) M353RS
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pA Replica Cosworth Body Components
Fiberglass body panels are an alternative to the more expensive, and
becoming unavailable, factory Ford versions. We have searched far and wide
to import only the highest quality fiberglass replica bodywork. Even so,
fiberglass is more prone to incidental damage (cracking) than the more
flexible ABS plastic or urethane original Ford components. Also keep in mind
that fitting is totally DIY and most items will require paint prep work, fabricated
brackets and other hardware.
Important Note: We often hear horror stories
from customers who have ordered similar fiberglass items from European
mail-order suppliers only to receive broken or substandard components, and
now you own it! Worse yet, the shipping costs involved importing large, bulky,
items like these can far exceed the cost of the part, and what started out as
a bargain now has become a expensive learning experience. Our pricing on
all items, including sheet metal & body panels,
includes inbound freight from
Europe. Once here, some items that are too large for UPS (or other carriers)
will be shipped truck freight collect, we will also extend our 25% C.F. Motor
Freight discount.
Front Spoiler Bumper (R/S Cosworth type) M353F
Front Spoiler Bumper (R/S 500 Type) with lower "splitters*" M353FA
*lower chin spoiler moulded in on lower edge
Rear Bumper (R/S Cosworth type)
Rear Wing Airfoil (R/S Cosworth type)
see information belowM306F
Rear Wing Airfoil (R/S 500 type) M306FA
Lower Rear Wing (R/S 500 type) M306L
Cosworth Wheel Arches (4) & Side Skirts (2)
see information belowM302F
Cosworth Hood (complete with vent louvers)
Hood Vent Louvers (2)
fiberglass (functional)M814F
Hood Vent Louvers (2)
stick-on ABS plastic (non functional)M814FS
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Cosworth Sierra Arches & Skirt
Sadly the factory Ford wheel arches have recently become unavaiable. Some
side skirts still remain but for the most part the R/S arches and skirts have gone
the way of all the factory R/S 500 stuff "not availabe- not replaced". In place
of the origionals we can offer a reasonable cost & quality fiberglass alternative
wheel arch and side skirt kit. For anyone searching out new factory arches and
skirts we might still have a couple odd arches & skirts available (no full sets)
call for more information & pricing.
Cosworth Wheel Arches (4) & Side Skirts (2)-
fiberglassM302F
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Cosworth Rear Airfoil
One of the trademarks of the Cosworth Sierra is its large rear wing/airfoil.
Perhaps a bit gaudy for some tastes, none the less it does a great job at
keeping the rear end planted. At speeds over 100mph as much as 45 lbs. of
downforce is created for added high speed stability. Anyone interested in this
item had one of two choices. The factory Ford Cosworth rear wing/airfoil (still
available from Ford Europe) but at over $1800.00 who can afford it. Or the
usual aftermarket fiberglass versions, although much cheaper in cost the
quality suffers greatly. When we sampled most of these we were genuinely
concerned that some of the replica wings might come apart, or even fly off at
speed ! This dilemma prompted us to undertake manufacturing a super high
quality fiberglass replica that solves all the above problems. It is extremely
well built, can be securely attached to the car and is attractively priced.
Note:
rear wings are designed to fit smaller hatch 1985-87 cars- the mounting foot
will overhang on the hatch glass molding on later cars and will have to be trimmed.
Rear Wing Airfoil (R/S Cosworth type) M306F
see above section for larger RS500 version
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Bodywork
(See Price List) (See Price List)
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