Making a 3dr cosworth into a 4x4?
19-11-2004, 03:21 PM
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Making a 3dr cosworth into a 4x4?
Can anyone tell me what is involved in turning a 3dr into a 4x4?
How hard is it and more important how much can you expect to pay for parts and labour?
Thanks for any help
How hard is it and more important how much can you expect to pay for parts and labour?
Thanks for any help
19-11-2004, 03:26 PM
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u need to make the gearbox tunnel bigger,u will also need the 4x4 g/box and diff.u need to add to the loom aswell.quite a big job.dont know bout parts and labour
19-11-2004, 03:41 PM
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Originally Posted by Mercury_Magic_S2
or porkie 
19-11-2004, 03:42 PM
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Originally Posted by Porkie
Originally Posted by Mercury_Magic_S2
or porkie
do i detect a tad bit of sarcasm there chap?
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19-11-2004, 03:58 PM
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Originally Posted by Porkie
Originally Posted by Mercury_Magic_S2
or porkie
20-11-2004, 09:49 AM
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Its not as hard as you may think to be honest!
The gearbox tunnel will need modifying on the drivers side to make room for the transfer box and if there arn't any there already a couple of half moon shape bits will need removing from the front chasis rails to allow clearance for the drive shafts.
Other than that the rest is a simple remove and replace with 4x4 parts!
The list is as follows:-
Sump + front diff
front driveshafts req'd
Engine mounts
oil filter remote housing
front crossmember
steering rack
hubs
tca's
front roll anti bar
front suspension
front brakes
gearbox and mount
clutch release bearing
exhaust
prop/s
There are probably some other odds and sods but thats all i can think of at the mo
The gearbox tunnel will need modifying on the drivers side to make room for the transfer box and if there arn't any there already a couple of half moon shape bits will need removing from the front chasis rails to allow clearance for the drive shafts.
Other than that the rest is a simple remove and replace with 4x4 parts!
The list is as follows:-
Sump + front diff
front driveshafts req'd
Engine mounts
oil filter remote housing
front crossmember
steering rack
hubs
tca's
front roll anti bar
front suspension
front brakes
gearbox and mount
clutch release bearing
exhaust
prop/s
There are probably some other odds and sods but thats all i can think of at the mo
20-11-2004, 05:29 PM
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I'm finding the gearbox crossmember is the biggest PITA. The one from the three door is the right width for the tunnel but wrong depth for the 4x4 box. The 4x4 crossmember is way too wide to fit the tunnel.
I will end up fabricating one, but it's been held on with string for months now 'cos I've lost interest in finishing it.
I will end up fabricating one, but it's been held on with string for months now 'cos I've lost interest in finishing it.
20-11-2004, 05:34 PM
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just finding my feet
Originally Posted by Mercury_Magic_S2
or porkie
was a relativly easy conversion, would deffo drive there again "
20-11-2004, 08:24 PM
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Originally Posted by The Knife
I'm finding the gearbox crossmember is the biggest PITA. The one from the three door is the right width for the tunnel but wrong depth for the 4x4 box. The 4x4 crossmember is way too wide to fit the tunnel.
I will end up fabricating one, but it's been held on with string for months now 'cos I've lost interest in finishing it.
I will end up fabricating one, but it's been held on with string for months now 'cos I've lost interest in finishing it.
I still have the modified one which was used on mine
21-11-2004, 07:39 AM
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I've converted a Mk1 XR4i to running full XR4x4 fulling gear with a 2.9 Twin Turbo.
Lot's of fun however biggest job involved is the tunnel. Dunno about the cossie shells but the early 4i shells have gearbox xmember mounts alot further forward than needed and I used the tunnel from the XR4x4 doner and used all of the mounts from that. Alignment of the box and prop is quite important so it one of those things ou wanna take you rime with
Also if mixing and matching mk1 & mk2 rear axle components remember the ARB setups are different and a lil extra work is involved here. but it is essentially a nut and bolt job onve the tunnel is sorted. the front half moons dont really need looking at, the shafts dont go anywhere near the chassis, however this was with avo coil overs.
Rob
Lot's of fun however biggest job involved is the tunnel. Dunno about the cossie shells but the early 4i shells have gearbox xmember mounts alot further forward than needed and I used the tunnel from the XR4x4 doner and used all of the mounts from that. Alignment of the box and prop is quite important so it one of those things ou wanna take you rime with
Also if mixing and matching mk1 & mk2 rear axle components remember the ARB setups are different and a lil extra work is involved here. but it is essentially a nut and bolt job onve the tunnel is sorted. the front half moons dont really need looking at, the shafts dont go anywhere near the chassis, however this was with avo coil overs.
Rob
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