change wheel FORD SIERRA 1992 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
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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
Driveline
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Automotive air conditioning components seem to be difficult to source and expensive to boot. The XR4 and Scorpio are no
exception to the rule. Reason being, a functioning A/C system is considered a "must have" and some will pay almost any price
for cold air on a hot day. BAT understands that comfort is paramount, but on the other hand it should not require a second
mortgage to repair your A/C system. You will find we have a selection of high quality, economically priced A/C parts too help
keep you cool without breaking the bank.
Most A/C Components for XR4 & Scorpio are interchangeable except where noted.
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Evaporator- The evaporator (alloy fin/tube design) works
as a heat exchanger. Air flowing through the core is cooled,
cleaned, and dried. It is also one of the major cost portions
of the A/C system, with the Ford original costing around
$550.00. Check out our aftermarket alternative for less than
half the cost !
M470E
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Expansion Valve- Meters the volume of refrigerant to the
evaporator. Expansion valve assembly should be replaced with
evaporator or if found faulty. M470EV
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Blower Motor- HVAC system blower motor includes motor
and fan wheel. (Scorpio) G470A (XR4) M470A
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Refrigerant Hoses*- The complete refrigerant hose manifold
assembly. These are specially re-manufactured units that have
the hose running to the fire wall extended so it can be routed
further away from the turbo's excessive heat. This is a very
common failure item. (XR4ti)
extended hose M470H
(Scorpio)
standard length hose G470H
*additional $100.00 core charge on this item- refundable on return
pE A/C Compressor- The compressor is one of the major cost
portions of the A/C system, with the Ford original costing upwards
of $850.00. Check out our
brand new Nippondenso A/C compressor
units that are complete including the clutch assembly.
M470C pC
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Clutch Assembly*- Replacement magnetic clutch
assembly. Available separately from compressor . If a clutch is all
you need we have it. M470CL
*additional $25.00 core charge on this item- refundable on return
pG Condenser- The A/C condenser (alloy tube/fin core)
is located ahead of the water radiator. Designed to cool
the compressed refrigerants air passes over the cooling
fins extracting heat to change hot gasses back to liquid
refrigerant as it cools. Again, one of the major cost
portions of the A/C system, with the Ford original costing
upwards of $600.00. Check out our aftermarket alternative
for considerable cost savings! for XR4 M470D
for Scorpio G470D
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Electric Fan- An alternative to the expensive original
condenser fan ($450.00). This highly efficient (1200 cfm) 16"
electric "pusher" fan moves more air
for le$$. A16F-PU
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Pressure Switch- The triple pressure switch assembly
engages the condenser fan and switches off the compressor clutch
with high/low pressure. Also a common failure item.
M470S
pJ Receiver/Dryer- Works as a storage/expansion tank for
refrigerant as well as a system dehumidifier. It is common to
replace the dryer when changing over to newer types refrigerants
or whenever the A/C system has been open to atmosphere as the
dryer is easily contaminated. M470R
Air Conditioning System2 4

Turbocharger
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pA Standard Wastegate Actuator Since the stock XR
wastegate is no longer available new, we supply a high quality
re manufactured unit. Internal components (diaphragm) are re-
placed and exterior is zinc plated.) M521WR
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Turbochargers We offer both re manufactured stock
specification and modified high performance turbos for the
XR. High quality re manufactured turbos include; new center
cartridge compressor/turbine wheel assembly with recondi-
tioned outer compressor/turbine housings, new bearings,
seals and O-rings and fasteners. Our high performance turbo
adds a few extra tweeks. A GNX compressor wheel machined
into the stock comp housing for an additional 30% airflow and
a 360 degree thrust bearing is fitted for added durability.
Turbos are fully dressed and include wastegate actuator,
base & drain gaskets and sold on a exchange "core" basis-
outright purchase will add an additional $100.00 to the cost.
Standard Reman. Turbocharger M522TR
High Performance Turbocharger M522TM
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Intercooler Kit If you are looking for a large high flow
intercooler kit this is the one to have. Intercooler core mounts
ahead of the steering rack in front of the engine facing the
ground. Air is ducted up and through the core. Plumbing is kept
short and allows for a larger core than what can usually be fitted
in the bumper/grille area. Kit is complete with intercooler core
(8" x 20" x 3.5"), mounting brackets, inlet plumbing pipes &
connectors, clamps, turbo output elbow, bypass valve and
additional hardware and instructions.
M522ICpD
Adjustable Boost Valve Kit Replace the troublesome
stock boost control solenoid with this easy to adjust under hood
boost valve. This kit uses a check valve to accurately control the
boost level which allows for faster turbo spool-up (reduced lag)
over typical adjustable "bleed-off" valves. This is a low cost modifi-
cation and should be a "must have" for all XR's.
M521BV
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Dual Port Wastegate Actuator These are new actua-
tors which feature an adjustable length rod (set boost & pre load)
and dual vacuum ports. The dual port feature permits use of a
remote mounted boost valve (see below), but can also be used
as a replacement for stock actuator.
M521WA2
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Cockpit Mounted Boost Valve Remote cockpit
mounted adjustable boost valve for use with dual port wastegate
actuators (see above). Vacuum signal is regulated by the in
car mounted valve and recirculated to the dual port actuator for
precise adjustment. M521TB
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Turbo Oil Feed Pipe is prone to cracking/leaking and
should always be replaced when a new turbo is fitted to assure
proper oil flow. Just look inside an old one and you will see
what we mean. M522P
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Turbo Inlet Hose we have a version of this (discontin-
ued by Ford) hose that links the turbo outlet pipe to the throttle
body. Ours is high specification 4-ply Silicone (blue) rated to
over 600 degrees, 190 psi burst pressure- better & cheaper
than the original ! M22H
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Stainless Base Gasket replacement for between the turbo
base and exhaust manifold. L521GT
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