cossy calipers on an S2
some1 should do a guide to such things as these questions keep comin up. it could then be put as a sticky thread. im just about to do the conversion on my car in next few weeks so i may do a photo diary of it in stages and do one, what ya all reckon?
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the easiest route to go is gettin saph 4x4 front callipers and saph 2wd discs. u can use your standard rs turbo brake hoses, but its very very recommended that u get braided ones available from burton performance for about Ł30. obviously pads needed would be 4x4 ones to go on the 4x4 callipers correctly. Apparently to make the calliper centralised over the disc, a 1mm washer is required. but as said, i havent done the conversion yet as i need to get some calliper carriers, so i will let u know how i get on wen i do them, hopefully in the next 2-3weeks
Originally Posted by ShandzS1
yeah they bolt on.....4x4 calipers with 1mm spacers and 2wd discs, sorted......
I did put on Mondeo V6 brakes (they are the same like cossie ones) 278 mm
and it didn't BOLT ON that easy. I had to drill hubs to accept thicker bolts. I had to buy longer bolts and I had to use 8 mm washer (I used a nut for that)
Here are some pics for you:





you can use washers (but I didn't like this method)
Jasus Maki,thats a very Mickey Mouse looking set up you have there!!!!!I think its safe to assume that the Mondeo brake calipers and/or disc's are different to the Cossie one's,as no way do you need to drill hub carriers or put in 8mm nuts to offset the calipers when fitting the 4x4 Cossie stuff.The set up on youre car looks dangerous!!!!
Regards,Micky
Regards,Micky
Originally Posted by Micky
I think its safe to assume that the Mondeo brake calipers and/or disc's are different to the Cossie one's,as no way do you need to drill hub carriers or put in 8mm nuts to offset the calipers when fitting the 4x4 Cossie stuff.
And to all those who think that there is some danger or it's done is some bad way I can say, that they do work and on very very hard conditions. So relax
Originally Posted by Maki
Originally Posted by Micky
I think its safe to assume that the Mondeo brake calipers and/or disc's are different to the Cossie one's,as no way do you need to drill hub carriers or put in 8mm nuts to offset the calipers when fitting the 4x4 Cossie stuff.
And to all those who think that there is some danger or it's done is some bad way I can say, that they do work and on very very hard conditions. So relax
see here too,Maki
https://passionford.com/forum/viewto...ight=2wd+dicss
Also look at www.escortrsturbo.co.uk No one over there is using 8mm spacers on their Cossie 4x4 caliper and 2wd brake conversions!!!!!
Originally Posted by Micky
....Plus every time 4X4 Cossie calipers and Cossie 2WD discs are mentioned on Passionford its always with 1mm spacers,not fecking 8mmm nuts!!!!
Originally Posted by Maki
Originally Posted by Micky
....Plus every time 4X4 Cossie calipers and Cossie 2WD discs are mentioned on Passionford its always with 1mm spacers,not fecking 8mmm nuts!!!!
Originally Posted by Micky
4X4 calipers are 1 pot,sliding caliper.Regards,Micky
heres one topic I took the info from:
http://www.fiestaturbo.com/forums/about132089.html
- cossie 4x4, mondeo V6(278mm), cougar V6, granada/scorpio cosworth callipers (all the same)
Maki...............you are a very brave (possibly bordering on crazy) man.
You see the pretty blue coloured bolts you removed...........
They aren't blue because the people at Ford though they would look good that colour....................
You see the pretty blue coloured bolts you removed...........
They aren't blue because the people at Ford though they would look good that colour....................
Originally Posted by SafeChav
They aren't blue because the people at Ford though they would look good that colour....................


Originally Posted by Maki
Originally Posted by Micky
4X4 calipers are 1 pot,sliding caliper.Regards,Micky
heres one topic I took the info from:
http://www.fiestaturbo.com/forums/about132089.html
- cossie 4x4, mondeo V6(278mm), cougar V6, granada/scorpio cosworth callipers (all the same)
Without a doubt using those massive nuts in between the hubs and carrier is compromising the strength, there will a lot higher chance of failer simply because the carrier will have that much more flex in it.
Originally Posted by Micky
Then why are you using nuts to give you a 8mm spaceing on youre calipers when everyone else who uses Cossie 2WD dics and Cossie 4X4 calipers only needs to use a 1mm washer?????I still think theres something not right,and it doesnt look safe to me or a few others on this post.Regards,Micky
So I'm not the only one. And I newer heard anyone get hurt by doing that.... I'm alive proof of that. I agree there can be more flex in this system but it is compensated by thicker bolts than standard RS ones
Originally Posted by Maki
Originally Posted by Micky
Then why are you using nuts to give you a 8mm spaceing on youre calipers when everyone else who uses Cossie 2WD dics and Cossie 4X4 calipers only needs to use a 1mm washer?????I still think theres something not right,and it doesnt look safe to me or a few others on this post.Regards,Micky
So I'm not the only one. And I newer heard anyone get hurt by doing that.... I'm alive proof of that. I agree there can be more flex in this system but it is compensated by thicker bolts than standard RS ones
Maki, I think SafeChav means you should of ATLEAST used some threadlock on that setup!!
I agree it DOES NOT look SAFE.
Howcome with the washer setup the bolt sticks out on the other side of the caliper but with the 8mm nut it doesnt, looks to sit flush with the caliper? Looks like you trimmed the bolt down to sit flush so it wouldnt touch the disc? GET SOME PROPER CARRIERS and threadlock the LOT
Also, by drilling out the hubs (I dont know how much) by the looks of it theirs less space between the bolt hole and the edge of the hub, this COULD crack!
End of the day mate, if you value yours and everyone else around you's safety I'd get it sorted
I agree it DOES NOT look SAFE.
Howcome with the washer setup the bolt sticks out on the other side of the caliper but with the 8mm nut it doesnt, looks to sit flush with the caliper? Looks like you trimmed the bolt down to sit flush so it wouldnt touch the disc? GET SOME PROPER CARRIERS and threadlock the LOT
Also, by drilling out the hubs (I dont know how much) by the looks of it theirs less space between the bolt hole and the edge of the hub, this COULD crack!
End of the day mate, if you value yours and everyone else around you's safety I'd get it sorted
I upgraded my standard brakes to 2wd cossie calipers on my s1. I bought the 2wd calipers by mistake... When i realised i had got the wrong ones to fit behind the standard wheels i thought... Sod it.
I fitted the 2wd calipers and ditched the standard wheels. They are absolutely fantastic. I had to drill the hubs (to 14mm i think) and machine 4mm off of the mating face of the caliper for clearance.
I run tarox drilled and grooved discs and tarox fast road pads.
Being unable to use the standard wheels is worth it when i use the brakes. A mate runs 4x4 calipers on his rs16i and IMO theres no comparison.
I fitted the 2wd calipers and ditched the standard wheels. They are absolutely fantastic. I had to drill the hubs (to 14mm i think) and machine 4mm off of the mating face of the caliper for clearance.
I run tarox drilled and grooved discs and tarox fast road pads.
Being unable to use the standard wheels is worth it when i use the brakes. A mate runs 4x4 calipers on his rs16i and IMO theres no comparison.
mate i have just finished mine today took me a week of evenings got about 10 cuts on my hand three blood blisters and 100 grey hairs. no not bolt on need a little tweeking here and there.
Originally Posted by vroooom ptssssh
Howcome with the washer setup the bolt sticks out on the other side of the caliper but with the 8mm nut it doesnt, looks to sit flush with the caliper? ...
we had a go at fittin mine this weekend. not alot of luck. ive got 4x4 front callipers and got the carriers off a mondeo v6 as theyre the same calliper. the hub had to be drilled out a little bit to accept the calliper bolts, and wen we trial fitted them, the disc is grinding against the carrier causng the discs to not be able to spin freely. anyone got a picture of their set up please. Oh yea and we had to use two 1mm washers to get the correct spacing
Originally Posted by marky_g
see my 2nd questions been answered 

You talking about the twin piston question???
Theres single pot which are 4wd, and 4 Pot which are 2wd.


