User Tag List

+ Reply to Thread
Results 1 to 37 of 37

Thread: Cossie diff install

  1. #1
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Cossie diff install

    Hi and here is my post about having to install a Cosworth 7 1/2 inch LSD into my MK2 Granada.

    Why so I hear you ask? It is no fun having 330 + BHP with an open diff. Exiting the chicane at Croft or Copse corner at Silverstone @ + 80MPH with the inside rear wheel smoking. I am extremely quick but when it really matters I can't get traction (exiting corners). Cars tend to pull away as I struggle for grip.

    Now Ford did make the Granada with an LSD fitted as an option. These were mainly on base model 2.8i traffic police cars and then in some 2.8i Sports/Injection models.

    These were very rare when the cars were a plenty & so no luck finding one now.

    Why the Cossie diff route? They are fairly hardy, abundant, and quite cheap.

    Here is a pic of the two diffs side by side. The Cossie one is the small alloy unit - you will see that they are ALMOST completely different. One saving grace is that the diff drive flanges are the same as my Granada and also the same spacing. As far as drive shafts go this unit bolts straight in.







    I did have to do quite a bit of chopping about of the main rear axle beam. The Granada diff had a long nose housing that used to bolt onto the rear beam. In order to allow a propshaft to run to the Cossie diff I had to drop the rear axle depth where the prop rund by 2 inches. I cut a 5 inch section out of the rear beam to allow this to happen. You will see some of the work in the following pictures. It was nerve racking putting an angle grinder through the main suspension componant of your track car.

    In order to replicate the front pinion shaft extension housing of the Granada diff I had to make up some bracketry to both hang the diff and keep the rear beam in place. Here are the pics.






    And you cant be too careful can you. I did this to stop the front bracket mount shifting back and forth. I picked up on the long bolt on the lower fixing point.



    I also had to think out how I was going to anchor the rear of the diff to the car. The original rear diff mounting hole in the body for the Granada was used. I again made up a good sturdy bracket for this. I did not want to rely on the top fixing alone and so took the bracket down and made a tube type fitment that will take place of the lower diff cover bolt.






    After using my old trusty diff case (seen in various pics) as my jig for making up the bracketry I have to make sure that every thing firt insitu on the car.

    Front bracket offer up



    Front bracket fitted to diff



    Front bracket to rear beam



    The last bit I have done is to clamp up and drill the pilot holes in both the front bracket and lowered rear beam section.





    Here are a few pics of the rear beam in the car and diff in place but with no front bracket. This is to give some idea of the fabrication required to do this project.





    I will post more pictures soon as I now have to take out rear beam & diff. I will dress the welds and have the rear beam and bracketry powdercoated. This is after I have drilled out the pilot holes from the pics to M10.

    You will notice that my car is black underneath. This is where the last owner sprayed it with oil every year to help preserve it. This it did but its a nightmre to work on - a bigger nightmare to clean off. I will get around to it though.

    Hope you have enjoyed this article. It is a little different to Escorts and gives the Cosnada some publicity lol.
    "I love you more than gummy bears"

  2. #2
    Pit Crew Decade Plus User

    Join Date
    Jun 2003
    Location
    CHESHIRE
    Posts
    1,605
    Thanks
    0
    Thanked 0 Times in 0 Posts

    Re: Cossie diff install

    Looking good you ben busy

  3. #3
    Pit Crew Decade Plus User nickmk11's Avatar

    My 1st Project
    Join Date
    Sep 2004
    Location
    uk kent
    Age
    49
    Posts
    1,332
    Thanks
    0
    Thanked 8 Times in 8 Posts

    Re: Cossie diff install

    nice to see a bit of modding going on ,good stuff, do you not think it will be a bit harsh without a bush in that diff rear mount ,could you not use the cossie one


    MOBILE REMAPPING KENT

  4. #4
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    I did wonder if the diff mount would be ok. I am not worried about noise and vibration transmission as it is only for the track now. It is going to be harsh but I can live with that. I only hope the rear casing copes with zero compliance.

    I chose to go this route as it was easier to fabricate. If I felt an isolator was required I would have engineered one in but it would have been quite a bit more work.

    I have a Cossie rear mount but can't really use it as the floor configuration is completely different to a Cossie. I would have ended up cutting the boot floor and main boot floor rear cross section up to accomodate it.

    Some kit cars have the diff solidly mounted and have their suspension anchores to the diff too.

    I will see how it goes. I will enjoy seeing people dissapear behind me instead of infront of me exiting corners now lol.
    "I love you more than gummy bears"

  5. #5
    Racer Decade Plus User robrs2's Avatar

    Join Date
    Jun 2003
    Location
    Teesside
    Posts
    3,026
    Thanks
    7
    Thanked 50 Times in 48 Posts

    Re: Cossie diff install

    looks like a good project. Are you doing any trackdays at croft this year?

  6. #6
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by robrs2
    looks like a good project. Are you doing any trackdays at croft this year?
    Hi rob, I really want to get to the Derby RSOC day this year. I hve got loads to do on the car though. Plenty of time though I guess. I am going to be fitting Cossie 4x4 rear disc set up as I burnt out the 2wd as you see on the car at the mo. This will be acompanied by a bias pedal box, braided lines throughout and Castrol SRF fluid.

    Was going for 400 BHP but this can wait - I will do more weight saving first.

    I will let you know when I have sent in my entry fee for the day mate
    "I love you more than gummy bears"

  7. #7
    Mechanic Mr_lizard's Avatar

    Join Date
    Jan 2006
    Location
    Southend, Essex, Innit
    Age
    38
    Posts
    673
    Thanks
    0
    Thanked 4 Times in 4 Posts

    Re: Cossie diff install

    Looks like a nice tidy install, good welding too mate!
    ------------------------------------------------
    One day people will stop asking 'Is that bit of your car supposed to be hanging off/leaking/on fire like that?'

  8. #8
    Racer Decade Plus User robrs2's Avatar

    Join Date
    Jun 2003
    Location
    Teesside
    Posts
    3,026
    Thanks
    7
    Thanked 50 Times in 48 Posts

    Re: Cossie diff install

    I heard Croft was selling quick.Got my entry in a few months back

  9. #9
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by robrs2
    I heard Croft was selling quick.Got my entry in a few months back
    Sending it off today Tim

    Going in the intermediate section. Can't wait now - got a real buzz looking forward to it. So glad I've done it now.
    "I love you more than gummy bears"

  10. #10
    TURBOSPORT SPONSOR Turbosport Subscriber
    Turbosport Moderator
    Turbosport Administrator
    Graham's Avatar
    My Race Car
    My 1st Project
    Join Date
    Feb 2006
    Location
    Ely, Cambs
    Age
    55
    Posts
    25,174
    Thanks
    297
    Thanked 2,286 Times in 2,095 Posts

    Re: Cossie diff install

    excellent bit of fabrication on that diff mount, i dont think your find the solid diff mount too bad noise and vibration wise, are you going to make the other axle mounts solid also, otherwise movment in them may start cracking things, as really everything needs to be either bushed or mounted solidly

  11. #11
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by graham bahr
    excellent bit of fabrication on that diff mount, i dont think your find the solid diff mount too bad noise and vibration wise, are you going to make the other axle mounts solid also, otherwise movment in them may start cracking things, as really everything needs to be either bushed or mounted solidly
    Hi Graham,

    Thanks for the + feedback mate

    I am running solid nylon bushes in the rear wishbones. These are non compliant really as they are totally inflexible. I chose this route instead of solid alloy ones.

    The main rear beam has poly type bushes with a shore rating of 95 which is really quite stiff. I don't know how I would mount the rear beam solidly right now - not really thought about it to be honest.

    Any further thoughts or suggestions are welcome - please
    "I love you more than gummy bears"

  12. #12
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    More pics.

    I have now removed the diff and rear axle beam from the car. I wanted to show the axle beam fabrication as it was a big step to take

    You will notice that I have two raised triangular supports with a bit of metal on each. This was my only mistake - I made a loop to go over the beam for rigidity purposes. I made it about 3mm too high and there was a foul. I will just weld the centre bit back in place as is because the metal I cut out removing it from each side is enough for clearance.

    Enjoy the pics:















    I will post some more pics when all powder coated and installed.

    I have now got to have the propshaft lengthened to reach the new diff flange location. The only down side to this modification is that I will have to remove the diff if I need to take the propshaft off completely as the rear end will be enclosed in the rear beam hoop etc. Its a small price to pay though. I think I can just undo both front & rear mounts and spin the diff on the drive shafts to allow enough room for the prop to be moved back so that the sliding joint can be released out the back of the gearbox.
    Last edited by Cosnada; 19-04-2006 at 19:57.
    "I love you more than gummy bears"

  13. #13
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    some fab work there
    were in the northeast are ya from m8 ? im from south shields

    MY MK1 ESCORT (Now turbo'd)

  14. #14
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Hiya Bud

    I am in Birtley.

    Scott.
    "I love you more than gummy bears"

  15. #15
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    not far from me then

    MY MK1 ESCORT (Now turbo'd)

  16. #16
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    In at the powder coaters
    "I love you more than gummy bears"

  17. #17
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    were the pics then scott hehehe was nice meeting you aswell m8

    MY MK1 ESCORT (Now turbo'd)

  18. #18
    World Champion Decade Plus User popuptoaster's Avatar

    My 1st Project
    Join Date
    Jan 2003
    Location
    Brentwood, Essex
    Posts
    9,508
    Thanks
    2
    Thanked 23 Times in 22 Posts

    Re: Cossie diff install

    Quote Originally Posted by Cosnada
    Now Ford did make the Granada with an LSD fitted as an option. These were mainly on base model 2.8i traffic police cars and then in some 2.8i Sports/Injection models.

    These were very rare when the cars were a plenty & so no luck finding one now.
    i had TWO, i had an early 4 speed manual 2.8i ghia S and a 5 speed 2.8i S (lovely dark blue with all the blacked out chrome on it)

    BOTH of em had lsd on and Both went down the scrappy after i cained the shit out of em for months. you can bet i regret it now.

  19. #19
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by popuptoaster
    i had TWO, i had an early 4 speed manual 2.8i ghia S and a 5 speed 2.8i S (lovely dark blue with all the blacked out chrome on it)

    BOTH of em had lsd on and Both went down the scrappy after i cained the shit out of em for months. you can bet i regret it now.



    I have actually saved 20kg's fitting the Cossie diff - I would do the change just for that
    "I love you more than gummy bears"

  20. #20
    World Champion Decade Plus User popuptoaster's Avatar

    My 1st Project
    Join Date
    Jan 2003
    Location
    Brentwood, Essex
    Posts
    9,508
    Thanks
    2
    Thanked 23 Times in 22 Posts

    Re: Cossie diff install

    my old 4 speed used to do 80mph in second gear, it went bang eventually though. lol

  21. #21
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by popuptoaster
    my old 4 speed used to do 80mph in second gear, it went bang eventually though. lol
    Why

    You liked the old Granada's then

    I must take you out in Cosnada and see if you can make out any differences from the ones you had

    Do you ever get up this way - Croft is soon
    "I love you more than gummy bears"

  22. #22
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    oi were the pics then scott

    MY MK1 ESCORT (Now turbo'd)

  23. #23
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Quote Originally Posted by Stevie
    oi were the pics then scott
    Hi Steve,

    Went round to the powder coaters today and they are having difficulty removing the old layer of powder coat I had done on the rear beam. It has been in the strip tank for a week now He assures me it will be ready tomorrow night.

    As soon as I have the bits back pics will be posted

    Any luck with the other chap and my fibre glass Steve?

    Scott.
    "I love you more than gummy bears"

  24. #24
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    not yet m8
    but i goto go for an interview at asda in boldon on tuesday

    MY MK1 ESCORT (Now turbo'd)

  25. #25
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Well, here is the latest update folks. I have had all the bracketry powder coated and have fitted everything back up into Cosnada.

    I spent about 5 hours today on my back under Cosnada trying to fit the rear axle beam and diff. The beam was by far the hardest part as I left the rear wishbones insitu. I fought, struggled and often pondered how the fook I was going to get it back together. I feel like I have been in the ring with Mike Tyson for 78 rounds.

    First off is the bracketry. I have added two side brackets to spread load. I am not using the top diff fixings but have put a brace up to them just for good measure really. For those who have followed this thread you will know I made a rear diff hanging bracket. I decided to beef this up a bit by doubling the thickness where it bolts to the car and also add in some strengthening triangles. Here they are prior to fitment:







    Here are the new diff brackets fitted to the diff - on a wheelie bin - they do have a use! Notice the heavy duty side brackets linking the top fixing points to the lower ones - just a load spreader really. Here we go:









    Prior to the diff going in I have of course had the rear beam powder coated too:





    So much better with paint on - and notice the replacement of the strenghtening hoop. Here it is installed in the car before the diff is fitted:





    Here is the piss of resistance - the diff is now installed!!!!!!!!!! Lots of pics here:



















    Well there goes folks! I have actually used a different diff to the one I originally did the fit up with. That one was not an LSD. This one is but its off an early Sierra. Early Sierra's had 108mm drive flanges but the Granada Cosworths and Cosnada run on 100mm drive flanges. What I need to do now is get a couple of early Sierra CV joints and fit them on my shafts at the diff end - problem solved.

    I was going to swap the drive flanges over but standard ones are not the same as LSD ones!

    Oh and yes I will be fitting a split pin in the rear diff mount nut!

    All I have to do now is extend the propshaft. Don't know if I am doing this myself or if I will send it to be done by a firm?

    The car can't come off its stands yet though as I am about to pull the rear brakes off as they are currently on ebay! I am upgrading to 4x4 vented with Green stuff pads and Castrol SRF fluid.

    Hope you have enjoyed this update folks
    "I love you more than gummy bears"

  26. #26
    Decade Plus User
    Turbosport Subscriber
    Dave's Avatar

    Join Date
    Oct 2003
    Location
    Cheshire
    Posts
    23,117
    Thanks
    167
    Thanked 694 Times in 516 Posts

    Re: Cossie diff install

    Well matey, I shan't pretend for one minute that I know what you are on about,
    But I can see you have put a lot of thought and effort into it, and that you are pleased with it.
    So, I'm chuffed for you

  27. #27
    Mechanic Mr_lizard's Avatar

    Join Date
    Jan 2006
    Location
    Southend, Essex, Innit
    Age
    38
    Posts
    673
    Thanks
    0
    Thanked 4 Times in 4 Posts

    Re: Cossie diff install

    Top install mate, good to see plenty of nyloc nuts too, plain ones scare me, especially with all the vibration in a race car!
    Good to see some proper original work thought out and done too!
    ------------------------------------------------
    One day people will stop asking 'Is that bit of your car supposed to be hanging off/leaking/on fire like that?'

  28. #28
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Hi,

    Forgot to add this pic - it was at Croft in 2004 that I hit the kitty litter at the end of the start/finish straight. All this came out of the propshaft centre bearing housing



    Gonna start a rockery
    "I love you more than gummy bears"

  29. #29
    Mechanic Mr_lizard's Avatar

    Join Date
    Jan 2006
    Location
    Southend, Essex, Innit
    Age
    38
    Posts
    673
    Thanks
    0
    Thanked 4 Times in 4 Posts

    Re: Cossie diff install

    stick it on ebay! Someone will probably buy that!
    ------------------------------------------------
    One day people will stop asking 'Is that bit of your car supposed to be hanging off/leaking/on fire like that?'

  30. #30
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Cheers guys for the good feedback

    I like to stimulate the grey matter with a good project or 2
    "I love you more than gummy bears"

  31. #31
    Racer Decade Plus User robrs2's Avatar

    Join Date
    Jun 2003
    Location
    Teesside
    Posts
    3,026
    Thanks
    7
    Thanked 50 Times in 48 Posts

    Re: Cossie diff install

    nice work again. looks the biz. Can't wait to see the result on track

  32. #32
    Racer Decade Plus User DarthVader's Avatar

    Join Date
    Jan 2004
    Location
    South Africa
    Age
    51
    Posts
    3,400
    Thanks
    21
    Thanked 36 Times in 35 Posts

    Re: Cossie diff install

    Some slick engineering there, well done

  33. #33
    Racer Decade Plus User Cosnada's Avatar
    My Race Car
    Join Date
    Jan 2006
    Location
    Sudbury
    Age
    53
    Posts
    2,979
    Thanks
    27
    Thanked 14 Times in 13 Posts

    Re: Cossie diff install

    Here is the latest update for Cosnada.

    I had to lengthen the prop so that it would reach the diff flange of the Cossie LSD. This was about 14" longer. I cut through a standard Granada propshaft and was really quite shocked at the wall thickness. I am very supprised I did not turn the prop into a bit of twisted junk

    Seeing this I decided I needed to go heavier than the standard 2" thin wall tube and so enlisted the help of COMMERCIAL PROPSHAFT SERVICES - 0191 482 1690. I took my prop in and told the guy what I wanted: Told him the length, that I wanted greasable and circlipped uj's (mine were steaked joints), I wanted it thick wall and that I wanted it balanced. He called me 3 hours later to say it was ready.

    I picked the prop up and to my delight they had completely manufactured a new prop. Did not use anything from my old prop. It has larger and stronger uj's, its 3" diameter thick wall tube and is exactly the same weight as my old one - mint

    Here is a pic of the standard prop and my new one side by side:



    The difference between uj sizes:



    Here is the prop fitted to the car now:





    And by the way I did fit a split pin in the diff rear mouning nut



    Just got to wait for my replacement 108mm CV joints and I can then say its job done!

    Will post more pics when sorted - on with the brakes now too
    "I love you more than gummy bears"

  34. #34
    Pit Crew Decade Plus User nickmk11's Avatar

    My 1st Project
    Join Date
    Sep 2004
    Location
    uk kent
    Age
    49
    Posts
    1,332
    Thanks
    0
    Thanked 8 Times in 8 Posts

    Re: Cossie diff install

    no hanging around there then ,top stuff


    MOBILE REMAPPING KENT

  35. #35
    Way too much free time Decade Plus User PIG's Avatar

    My 1st Project
    My 2nd Project
    Join Date
    Oct 2004
    Location
    get me on my beeper,beeper
    Age
    53
    Posts
    15,806
    Thanks
    38
    Thanked 140 Times in 130 Posts

    Re: Cossie diff install

    excellent stuff scott,glad its coming along m8

  36. #36
    Racer Decade Plus User Stevie's Avatar

    Join Date
    Aug 2002
    Location
    Geordie Land
    Age
    55
    Posts
    2,485
    Thanks
    8
    Thanked 11 Times in 10 Posts

    Re: Cossie diff install

    thats mint m8

    MY MK1 ESCORT (Now turbo'd)

  37. #37
    Tyre Kicker

    Join Date
    Aug 2006
    Location
    CzechRepublic/Praha(Prag)
    Age
    44
    Posts
    41
    Thanks
    0
    Thanked 0 Times in 0 Posts

    Re: Cossie diff install

    wo0ow that is cool man...
    i will try that...

    thx for the photo's
    l.

+ Reply to Thread

Similar Threads

  1. Nearly there with body mods for cossie install.
    By miikk in forum Restorations and Projects
    Replies: 45
    Last Post: 03-03-2005, 14:51
  2. COSSIE REAR DIFF
    By flannigan in forum Message Centre
    Replies: 5
    Last Post: 07-01-2005, 19:02
  3. cossie diff and front seats
    By cossie400 in forum Parts For Sale
    Replies: 2
    Last Post: 05-01-2005, 20:50
  4. cossie diff
    By nugnah in forum The Technical Section
    Replies: 2
    Last Post: 11-07-2004, 17:41
  5. Cossie Diff problems
    By denkelly in forum The Technical Section
    Replies: 0
    Last Post: 30-03-2003, 15:08

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts