Hi all im after a bit of help if possible. I have a 1.6 3dr sierra shell and i also have a 3dr with a 2.9 v6 4x4 engine fitted but the shell is absolutley rotting! and im starting a total swap to the 1.6 shell and was wondering if there are any complications in doing so? for e.g would i need to change all the wiring to the rear lights and also can i use the fuel tank from the 1.6? any help would be great. Thanks in advance.

 

no clues anyone?

 

You are going to a need an EFI fuel tank, pump and lines along with the pump wiring.

Can't see why you would want to change the wires to the rear lights

If the rotten 3 door is 4x4 you will need to modify the transmission tunnel in the better shell to clear the transfer box.

 

I`d swap everything, its all tested and working,
no workarounds will be needed, if you cut no corners,

 

i didnt say i wanted to change the rear lights wiring thats why i was asking IF i needed to change the wiring.. The rotten 3dr is a cosworth shell with the original engine sold and somebody has put the 2.9 4x4 in it (dont ask me why) also theres a lad on here this link https://passionford.com/forum/restor...6-shell-2.html that rekons he never had to modify any of the tunnel etc?

 

Hi
I can tell you if your 3door she'll is a mk1 the transmission tunnel will be different for 4wd

 

The lump where the transfer box is will need cutting out and a bulge putting on the side to clear.
I've seen people take a large hammer to the tunnel or other weld an xr4x4 item in place giving the slotted gearbox mounts. Something to consider?

 

yep needs to be done to clear , mines is done (p100) , mines was cut out as to try and bash that part out would be a nightmare tbh its quite solid

 

My 3 door cosworth runs 4x4 sapphire cosworth running gear ,with no mods to the shell

 

The tunnel needs a small cut out for a 4x4 gearbox, don't know how anyone as mentioned above has done it without this cutout? As it just doesn't clear in mk1 Sierra 2wd shells, the thread you posted saying it fits was for a t5 2wd gearbox which does fit without modification to the tunnel, I think you have to cut a notch in the front chassi rails too so that the front driveshafts don't hit if I remember correctly, you're better off changing everything over to the 1.6 shell as all lights etc fit the same

 

thanks lads

 

yep I cut the tunnel and the half moons in the front chassis legs , don't hit but better to have a good bit of clearance for peace of mind