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Cosworth 4x4 brakes on XR4x4 - help!!!!!

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Old May 20, 2006 | 04:16 PM
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Iain Mac's Avatar
Iain Mac
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Default Cosworth 4x4 brakes on XR4x4 - help!!!!!

Here we go again.

Had the car in the local garage today for a shakedown inspection and to tighten various things as well as fit exhaust and fuel pipes, finish brakes, and swap drivers side hub to Cosworth.

Mechanic tells me that the front end isn't right, and I'm looking for pointers to fix it.

The TCA balljoints are having to sit at an outrageous angle that doesn't appear to give much room for any movement (both lean in very heavily, which makes fitting the hub a task).
You can see the whole engine etc moving when you rotate either front wheel. Mechanic tells me that the driveshafts are too tight and the springs in the diff ends are under full compression, so no room for them to adjust to avoid this wind-up.
Are the TCAs at fault? It looks like the section from roll bar to ball joint could be longer and at a steeper angle to match the bottom of the hub.
Should I be using the shorter Cosworth driveshafts? (But my springs are -25mm, so wouldn't they then be prone to popping out?)
Car is a 3 door XR4i fitted with all the 4x4 gear from a 92 XR4x4 except hubs and brakes from Cosworth 4x4.
TCAs were bought new for XR4x4.
It has an XR4x4 rollbar.
I'm using new Koni struts bought for an XR4x4.
Cosworth 4x4 hubs are being used.

C'mon guys, today has been a MAJOR downer - how do I fix it?
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