Ford Sierra Front Differential Cover

This project will use a Ford Sierra Front Differential 4×4, 3.92:1 front differential (from a non-Cosworth Sierra 2.0s 4×4). Normally this diff would bolt to the alloy sump with integral drive shaft. However, for this application the diff will be mounted in front of the engine, with a custom drive-shaft assembly.

The drive-shaft assembly will also incorporate a diff strengthening plate between the diff and the bottom cover.

The first stage in creating a front axle assembly started with drawing up the bottom differential cover.

Click here for more info on the Ford Sierra Front Differential

Sierra 3.9:1 Front Differential

It's been a few weeks since my last blog and for good reason. My project has a new home. I had to knock down walls and do some pretty scary electrics, but the work is coming to an end. The next job is a heavy duty chassis table. More

Granada 4x4

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Modified Front Sierra Differential

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Sierra 4x4 Front Driveshaft Cover

This Sierra 4x4 Front Driveshaft Cover forms part of the Cosworth front axle assembly normally bolts to the nearside of the sump. In this design however, it will be mounted to a custom axle assembly. The cover would normally bolt to the right hand side of the sump / shaft assembly

Ford Sierra Front Stub Axle

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Locost 7 4x4 Front Propshaft

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Ford Sierra Front Differential

With all off the front suspension brackets welded into place the next job is to mount the front 4x4 differential assembly. The nearside suspension brackets took a fraction of the time that the offside did. With the aid of a simple jig and a couple spirit levels, four mounts were

Kit Car 4x4

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