Cosmo

Wondering if anyone can help, am re-shelling my sapph cosworth into a 3dr shell, however its not an original cosworth shell, its originally a 1.3. I want to mount the t5 gearbox out of the sapph in it, which cradle do i need? would the sapph one do or do i need an original 3dr mount?, or is it neither and do i need to do some fabrication work? I've offered the box up and it appears to fit the transmission tunnel ok.

Any advice is much appreciated!

Cheers

Lee

AndyPen

iTrader: (24)

There's another thread on here that says they are pretty much the same mate. Not sure about the chassis mountings though and they may have to be sorted - anyone know for sure?

Heres the recent discussion...

https://passionford.com/forum/ford-sierra-sapphire-rs500-cosworth/241974-2wd-transmission-mount.html

tabetha

Afaik the 3 door just has a steel support for the actual mount whereas the sapphy is alloy.
Every sapphy I have looked at has extra slots near the used ones presumably for a different mount support as in 4wd one.
I realise yours is 3 door, but ford are not going to make seperate shells for the sake of a mount between 3 door 1.3 and cossie, so either a sapphy or 3 door mount will fit straight on.
tabetha

dojj

iTrader: (3)

the earlier shells were fairly different when it came to the transmission tunnel as they crumpled up fairly spectacularly

something to look into when you find the actual build date of the shell

Cosmo

Cheers gents thats spot on! I do have one further question, on the sapph middway down the prop shaft i have another (smaller) bracket that holds it straight it appears, will i require this bracket removing and putting on my 3dr shell also?

dojj

iTrader: (3)

yes, you will need to transfer that over as that's the prop bearing
make sure you note the amount of washers used to space it out and make it straight as going a bit out can make it vibrate something chronic

Cosmo

Should i use the prop off the sapph then also, i got one with the 3dr, was going to use that but if using the sapph one is better then i can, i'm guessing they're the same though?

Cheers!

dojj

iTrader: (3)

use the one that goes into the end of the gearbox
the other ends are all the same, but rememerb that the bolts and holes are arranged in a rectangle, not a square so they might not line up first time around

Cosmo

Spot on mate, am a little worried though as the 3dr came with a 4x4 cos rear beam fitted, so am guessing its a 4x4 rear diff, will my 2wd prop go into the 4x4 diff ok? This is the trouble with buying part projects!

Jasesapphy

iTrader: (1)

it will blt up fine, but dont know how long it will last, really you should have the bigger diff and beefier shafts for 2wd

you could sell your beam and by a good 2wd complete beam

tabetha

I fitted a complete 4wd beam to my dads xr4i, and have no problems five years later with the diff, the prop SNAPPED in two though, and twisted like a banana!!
The diff seems plenty strong enough for low down V8 grunt, but had to have a new prop made.
tabetha

Cosmo

Question is then gents do i need to change my diff and drive shafts to 2wd ones or should i leave the 4x4 one there, i'm looking to run a 350bhp motor ultimately.

I've got a second question which is that if indeed i do need to use my 2wd diff (which i stripped off my sapph today) will it fit the 4x4 beam and the driveshafts fit the 4x4 hubs? The reason i ask is that my 2wd beam and hubs have seen better days and i dont really want to use them.

Jasesapphy

iTrader: (1)

2wd have 108mm drive flanges so no, also the diff wont fit into the beam

Cosmo

I'm in two minds now though, sounds like the 4x4 diff is fairly strong, will it take a well tuned cossie lump though? Obviously leaving the 4x4 beam on is ideal as it saves me a lot of effort

Plus it looks like my 2wd diff isnt going to fit my 4x4 beam.

tabetha

The 2wd diff can be fiotted very easily by cutting 1/4" of the top rear mount either side on the diff casing, it can still then be used in either just by adding a spacer or washers.
My dads car is 240lbft at 1200rpm so gives the diff a workout, saying that as I remember at the moment we have a 3.13:1 DIESEL DIFF in it and that has lasted, DONE AT LEAST 5000 miles, and it is given some stick, enought stick to snap a prop in two.
tabetha

Cosmo

can you explain that for me a bit mate please, where do i need to trim the diff? on its rear mount? any chance you got a pic?

Also would i be able to mount 2wd hubs on the 4x4 beam as i wil need to if the driveshaft splines are a different size.

Plus has anyone got a spare 2wd drive shaft as i mullered one getting it off yesterday (dam nut stripped the threads on it!)