SUSPENSION AND BRAKES
A stock Sapphire 4x4 feels stodgy and lifeless compared with a rear-wheel-drive Cossie. Factor in three decades’ wear, and it won’t be much fun.
Chief culprits for poor handling are tired suspension bushes: worn track control arm bushes cause wandering from the front end; trailing arm bushes result in sloppiness at the back. Powerflex polyurethane replacements are the simple and permanent solution.
Vagueness at speed could also come from the steering. Knackered steering column bushes cause a lack of feel, and the Sapphire is prone to looseness at the steering rack, so jack up the car and feel for play. Check for oil leaks from split gaiters, and make sure the PAS pump isn’t noisy.
Bushes can cause clonking noises, but check for broken coil springs or tired dampers. It’s normal for Sapphires to be on aftermarket suspension, which generally improves handling, but coilovers are too stiff for a road car, and a drop greater than 25mm risks damaging the CV joints.
Sapphire 4x4s lacked the four-pot callipers of their predecessors – instead fitted with Scorpiotype floating callipers – but at least the rear discs were ventilated. The pedal should be firm and communicative, and with decent fast-road pads the stopping power is acceptable. But compared to a modern machine, a Cosworth with duff brakes will feel lousy and downright dangerous.
Juddering felt through the brake pedal and steering wheel is typical of contaminated discs and/or pads, although it’s worth checking broken suspension components aren’t at fault. Pulling to one side under braking suggests a sticking front calliper; seized rears are particularly common, especially on the handbrake mechanism; jack up the car and check with it in the on or off position.
Cosworths used a decent Teves ABS setup, which commonly causes problems from dirty/ faulty wheel sensors or broken wiring. A failed ABS pump, blown fuses and fluid level sensors could also be to blame.