Hi to all hope ya enjoying the snow,,
now down to the questions,,
can a standard 3dr shell have all the running gear from a saph 4x4 fitted to it,
or do ya need running gear from the old xr4x4 wats best,,
how about dash and loom from saph, or is it best to splice old loom or,
is this major headach stuff. im not worried about the greese side of it, not to keen on sparks side or is it pretty much plug and play,, is there any thread or info about how to do or has any passion ford lads done b 4,, cheers people steve

 

Yes it can, you need to modify the floor slightly for the box, and you need to cut the half moons for the driveshafts.

Martin Hadland is the best man to ask, he has done several I believe

 

Cheers Chip, whos Martin Hadland is he a pf lad,, or a site to look at cheers

 

Sorry mate, thought everyone on here knew Martin.

He owns "reyland motorsport" near birmingham, they build all sorts of cool and crazy stuff

 

The loom isn't a straight swap for a lot of reasons, but it can be done: the bulkhead is a different shape, the fixings for the fusebox are different, the connectors on the door-looms are different etc, etc.

I didn't bother with the half-moons in my chassis legs and had no problems so far - I just removed the flange that sticks down and seem to have enough clearance with a -25mm drop.

The tunnel needs a bulge to take the transfer box and I'm not entirely happy with my transmission crossmember so I'm open to suggestions/pics of anyone else's conversion.

 

would it be just as easy to cut the tunnel from the donar 4x4, or more work 4 no reason, cheers 4 info lads keep it coming,,

 

I cut out a tunnel for the first 4x4 I made, and thought modifying would be easier for the second.

Given the fact I'm not happy with the crossmember, I'd do the tunnel transplant if I was doing it again.

 

over all was it an easy transplant,, any problems ya found afterwoods,,

 

The crossmember and the loom are the only real issues.
For instance, the fusebox took some work to mount and is another area I'm not 100% with..
Also, the later cars have two big holes under the battery for different bits of the loom to come through, but my 4i only had one - I managed to get all the wires through that though.
Then fixings for ABS etc had to be fabricated (3dr may already have these).

 

i cut the outer skin out of my chassi legs and the half moons were under it so i seam welded it thats easy, is their not too sets of holes for the gearbox crossmember so you just buy 4x4 one and bolt it in ? dont think you need to mod tunnel that much for the box either? i cut mine out and welded it up but think you could hammer it if last resort

 

i do like the word hammer many a job done with a good hammer,,

 

Borrowed some pics from a friend.

 

thanks 4 the pictures greatfull have better understanding now,, thanks kverna

 

No need to swap tunnels, just take a small section out where the transfer chain cover is on the 4x4 box.

If you stick with the original tunnel then use the alloy gearbox crossmember from a mark 1 2.8 4x4 sierra the one fitted with the t9 box - it fits directly to the mt75 4x4 box from the cosworth and mates up to the original runners fitted in the tunnel, lining up the box perfectly.

meant to say cut the notch of alloy sticking out on the side of the transfer chain cover in the above pic as that helps with clearance as well

 

cheers guys