differential FORD SIERRA 1991 2.G XR4 Workshop Manual

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 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

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

pA
pB
pC
pD
pEpF
pHpI
pJ
pG
Transmission & Related Components
pHShifter- A serious short throw competition gear lever
featuring a robust large diameter shaft placed within a
spherical bearing. The all metal construction will cause
additional transmitted noise but this is a small penalty to
pay against the strength, speed and quality of the gear
change achieved. M717
pIGear Oil- Torco synthetic gear oil is designed to
withstand tremendous heat and provide extreme anti-
score protection under high torque "shock loading"
conditions. That is why most Indy car and drag race teams
rely on Torco protection. Torco SAE 75w90 gear oil is GL-
6 rated and includes limited slip additives. Great for both
transmission and differential applications. Torco synthetic
gear oil greatly improves the shift "feel" of T9 transmission,
shifting becomes light and precise, almost like a tune-up in
a bottle. Notes: transmission will require 2 quarts (2.25 to
3.34 pint capacity depending on year) and rear axle 1 quart
(1.6 pint capacity) Gear oil not for T5 transmissions (use
ATF type fluid). C2S
pJQuadrant & Pawl Kit- When the clutch pedal "ratchet
adjuster" wears out it contributes to poor pedal feel and an
annoying clicking noise. Renewing the quadrant and pawl with
this handy kit will alleviate the problem. M368
pK Rebuilt T9 Transmissions- Highest quality factory
certified remanufactured T9 transmissions with European
gear ratios (3.65:1, 1.97:1, 1.37:1, 1.00:1, 0.82:1). M700
pAOil Seal- input Shaft (front) T9 TransmissionM703
pB
Gasket- input bearing retainer to main case (front)
T9 TransmissionM702G
pC
Gasket- top Cover T9 TransmissionM716
pDOil Seal- extension housing (tail shaft) T9
TransmissionM719
pE
Gasket- adaptor plate (bearing carrier) to main case T9
TransmissionM709
pFGasket- adaptor plate (bearing carrier) to extension
housing (tail shaft) T9 TransmissionM708
pG Short Shift Kit- If anything can be added to enhance
the "link" between driver and transmission while rowing through
the gears on the XR4 or Scorpio 5-speed this is it. We have a
dynamite quick shift kit that fits standard T9 Hummer transmis-
sions. If you like the shifter "feel" on Hurst equipped Mustang
GT, this kit offers similar results. Customers often remark that
this shift kit is one of the best modifications that they have made
to their cars, especially considering the price and ease of
installation. Just think about how many gear changes you make
in a day, let alone a week, or year. Shouldn't every shift be quick,
light and precise? M715
pK
3 2

Complete Rear Differential Assembly- New assembled
Ford rear differentials with limited slip (3.92:1 ratio). Remove
old center section as a whole and replace. Not inexpensive,
but a value when you add up the individual component costs
and the labor charges on a rebuild. $1995.00
pA
Ford LSD Unit- as standard on some European Sierra
models. For std. 7.5 ring & pinion $1425.00
Quaife LSD Unit- none better for ultimate strength and
smooth performance. For std. 7.5 ring & pinion- includes
Cosworth size (large) drive flanges.
See page 10 for more
information on this item.
M710 $1245.00
pB
Crown Wheel & Pinion- new Ford ring & pinion sets. For
automatic (3.36:1), manual ( 3.64:1), optional (3.92:1).$550.00
pBCrown Wheel & Pinion- new Ford Rally Sport 4.44 racing
ring & pinion sets.$995.00
pCBearing & Seal Repair Kit- complete differential housing,
bearings, oil seal, o'ring. (each) per side
M721 $94.50
pD
O' Ring- differential bearing housing o'ring
M722$1.98
pE
Oil Seal- differential bearing housing oil seal
M720$8.35
A
C
G
I
HJ
K
L
MNB
O
FD EC
pFOil Seal- pinion oil seal M725$13.20
pG
Flange Nut M726$3.65
pH
Flange Assembly$63.50
pI
Pinion Nut M727$13.05
pJ
Roller BearingM723 $59.00
pK
Crush Collar M729$5.49
pL
Spacer$3.75
pM
Roller Bearing M724 $59.00
pN
Shim- specify size when ordering$4.03
Gasket- Rear Differential XR4 & Scorpio M730 $8.15
pO
Differential to Body Mount -XR4 M430 $79.50
pO
Differential to Body Mount -Scorpio G430 $79.50
Rear Differential Components
Note: most differential components are similar
for XR4 and Scorpio.
34