Ford Sierra Cosworth Transmission and Rear Axle

Important Notes on Disassembly and Assembly (cont'd.)
To fit the 5th gear to the main shaft, the gear should be heated up to approx. 600° C using a hot air blower. When disassembling the gear shift cover make sure to mark the shift forks and to set the shift segments and the shift lever in neutral position.
Further detailed instructions on "dismantling and assembling of the gear shift cover" are contained in the Sierra RS Cosworth Workshop Manual. Before fitting the transmission extension, the cranked selector lever with détend ball and spring have to be fitted.
1 = Roll pin
2 = Cranked selector lever
3 = Détend spring
4 = Détend ball
5 = In neutral position install détend ball into détend plate.
Secure cranked selector lever by the roll pin after fitting the transmission extension.
Before fitting the gear shift cover, measure end play of the main shaft as follows
- Install dial indicator gauge (see illustration), turn the input shaft and watch deflection of pointer on gauge. Set gauge to zero.
- Using a suitable piece of wood force input shaft upwards and note dial gauge reading.
— Dial reading = shim pack required Specified end float: 0±0,5 mm
— Fit required shim pack between bearing outer ring and input shaft bearing retainer. (For selection of shims see Technical Data)
Rear Axle and Suspension
• The Sierra RS Cosworth is fitted with the independent semi-trailing arm rear axle, coil springs and double-acting telescopic shock absorbers as known from the Sierra vehicles.
• The rear axle incorporates a viscous-coupling limited-slip differential, which gives full control over wheel-spin and greatly improve traction and roadholding in all driving conditions.
• All components of the Sierra RS Cosworth rear axle which have been modified in comparison to the Sierra are mentioned on the next page.

Source
• No new special tools are required.