Caddyshack

Does anyone know if the front hubs, discs and callers are different on a cossie 4x4 to an xr4x4.

The reason I ask is that I am having a problem fitting the reyland front brake upgrade on my pug 205 4x4 cossie.

The rears had 2wd discs and callipers so I had to swap out the hub / bearing carrier to a4x4 one and also buy 4x4 rear calipers and then do the mt morotrsport rear upgrade.

Now the fronts are causing issues and I noticed that my current discs have a smaller offset than some spare 4x4 discs I had. My only guess is that I have xr4x4 hubs and probably clippers too, or just calipers?

I cannot think of any other ford 4x4 that would have given up its running gear to suit the cossie conversion in 4x4?

Any help much apppreciated

nicksaph

front hubs for the XR4x4 are different to the 4x4 cosworth items.

post 11 on the link shows the difference.

https://passionford.com/forum/genera...ront-hubs.html

MK MOTORSPORT

iTrader: (1)

your front bells should be flat on a 4x4

Caddyshack

Thanks to you both. I think I must have xr4x4 hubs then, I THINK the carriers might be different too.

My bells on the reyland kit are flat. It is my spare standard 4x4 cossie discs that have a larger offset than my current discs on the car. I bet I also have the XR longer driveshafts which might explain the front vibration when turning.

Now to track down the parts I need!

james kiely

iTrader: (5)

you probably had 2wd offset discs as they work with the xr4x4 hub .as far as i remeber they changed the hubs from the xr to the cossie to allow for the wider wheels

Caddyshack

I assume by swapping to cossie 4x4 hubs my track won't change? I expect the geometry might?

I must have spent 3-4 hours trying the reyland conversion.....I thought I was going daft!

MK MOTORSPORT

iTrader: (1)

just mod or remake brackets

Caddyshack

The problem is that the brackets do not allow enough room for the bolts that hold the brackets on to the hub, they are already domed cap heads for room but I would need about 5 mm removing, I think I would need to counter sink and if you do not get them 100% straight it would cause an issue.

I will have a think but if not it will be new hubs

james kiely

iTrader: (5)

a pic would help mate

neilnewboy

iTrader: (1)

From my understanding ur track won't change, the angle that the shock sits at will be different on an rs hub compared to that of an xr hub, u can run a wider wheel(barrel side/inner lip) and it not foul the spring because the extra angle gives more clearance.

Caddyshack

I really appreciate all the help you lot are giving.

I will do some pics soon

At least if I build up new hubs I can paint them after new bearings are fitted, like I did on the rears....just more money.

james kiely

iTrader: (5)

some people use the xr shafts if their car is very low and the extra length due to the angle of the shaft helps them to stop popping out.the down side is they can grind in your cv joint and break up.

Caddyshack

When Mark Shead had the car he said he also felt a vibration when turning and suspected the drive shaft angles. I might try a set of new cossie ones and measure them up. I had read about the lowered cars...it is hard to say with mine being a pug 205 but it isn't all that low.

Marc sierra

iTrader: (1)

Cossie hubs will give a smaller track than the XR hubs, the difference is quite big, that's also the reason why the XR has longer driveshafts.

Caddyshack

I suspect the XR stuff is on there due to the availability of cossie parts in the 90s but it could have been for track reasons as my t16 arches are quite wide. I have not ruled out different wheels as my tyres are only 195s and 500 ft lb of torque is going to work them hard so would not mid 8 inch rims.

Caddyshack

One extra question.....are the escort cossie hubs different to Sierra ones?

james kiely

iTrader: (5)

escos and sierra hubs are the same mate.

Marc sierra

iTrader: (1)

The same as sierra Cosworth 4x4 hubs, but obviously different from sierra xr4x4 hubs.

But having cossie hubs isn't necessarily better than the XR hubs. They give a different track width and also roll centre.

Caddyshack

I need the cossie hubs to be able to fit my new brakes unless I can find a simple and safe solution but I think I would need to remove metal in a few places which is never a good feeling with brakes.

Marc sierra

iTrader: (1)

I would decide the hubs based on how the wheels stand in the arches. If they don't stick out with the XR hubs than that is fine.

I also have a 320 mm Reyland kit, but the reason for that is the cossie hubs with the very low offset give hardly any room for calipers with multiple pistons. The XR hubs that have that problem. So if the XR hubs wouldn't make the wheels stick out that far on my Sapph I would have used them to fit some decent calipers.

You could also use deeper bells to solve the problem.

Caddyshack

The problem is that the adapters will not fit the XR hubs, there is not enough room for the bolt head to fit between the fixing point and the carrier. I will get my mate to have a look as he is an excellent fabricator and may solve the problem.

On the mk kit and on the reyland kit there are no instructions so there is always a nagging doubt that you have missed something but I am certain I have not, if anyone has a pic of the reyland adapter on their cossie that would be great. I will add a pic up and also chat to reyland.

Marc sierra

iTrader: (1)

It sounds like the bracket is on the wrong side of the caliper mounting lugs.


This is the 320mm bracket (slightly different) fitted to my sapph.

Caddyshack

Thanks Marc, that photo confirms that I do have it on correctly.

It is the top part that I am struggling with but I have worked out that if I take 1mm off the top of the domed cap head once it is tight and leave out the washer then I get enough room. I also need to remove a little bit off the reyland spacer with the flat on it but it just needs 1mm off the face of the flat.

I really appreciate you taking the time to add the pic for me as I have gone back out and mocked it up and now it works with the amendments I have suggested.

Caddyshack

Old thread. I measured my actual front shaft today, drives side at 34.6mm. Does anyone know the actual lengths of Cossie and xr4x4 drive shafts. I know the 4x4 is about 15mm longer but don't know the actual shaft length.

Also, on my old shafts there is a circlip with holes for the pliers to remove them...nice and easy. This is at the brake end and the circlip holds the shaft in the hub...on my other shafts the circlip doesn't have holes and try as I might I cannot get the circlip out of the way enough, is there a tool or technique for removal?