Suspension Mounts

I’ve done the mounts for the front suspension A-arms and the Sierra Front 4×4 mounts.

I’m not the first to mount a 4×4 front diff into a Haynes Roadster and at the speed I work at it’s not surprised. It’s not just a case of welding on some brackets there was a ton of calculations.

The differential mount also incorporates a diff strengthening plate.

Sierra Front Diff Strengthening plate

Normally, the front differential mounts to the side of the sump. A central drive-shaft passes through the sump, to where the nearside drive-shaft mounts. With this set-up the differential is mounted in front of the engine. A custom central drive-shaft assembly is needed.

Sierra Cosworth Front Diff Assembly

Hopefully, the whole assembly should increase the strength of the differential casing. In high powered cars the front differential has been a source of failure.

More Ford Sierra Front Differential information here

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 good ...

Modified Front Sierra Differential

Unlike the Rear Sierra Differential, the front differential is not located along the vehicles' centre-line. The prop-shaft driving the front diff exits the side of the MT75 gearbox and travels forward to the front differential bolted to the side of the sump. The front differential mounts only to the engine's ...

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

I'm getting better at the CAD stuff. The latest item to get drawn up is the Sierra Group N front stub axles. When I started learning AutoCad this would have taken me days if not weeks to draw. These took about under an hour to measure up and they ...

Kit Car 4x4

I now have all the pieces cut ready to take to the specialist TIG welding company. It'll look much better once all the sticky tape is removed! There was a stage when I was worried that the assembly would be a little weak, yet this mock-up is roughly stuck together ...

Kangaloosh

Front suspension design has been complicated by the 4x4 running gear. It quickly became obvious that it would be impossible to use the ubiquitous Ford Mk2 Escort steering rack as it would try to pass straight through the Sierra Front diff. The push rod for the coil-over shock also tried ...

Side tracked

Not wanting to simply bolt together a bunch of components from a list of donor vehicles, just because they fit, the intention is to use modern suspension analysis software such as Kangaloosh to model all I can. In order to analyse anything, it became annoyingly obvious that I would need ...

Ford Sierra Front Differential Cover

This project will use a Ford Sierra Front Differential 4x4, 3.92:1 front differential (from a non-Cosworth Sierra 2.0s 4x4). 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. ...

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