Ford Sierra Cosworth T5 Complete Hydraulic Clutch Conversion Kit

Ford Sierra Cosworth T5 Complete Hydraulic Clutch Conversion Kit

Complete hydraulic clutch conversion kit for Ford Sierra Cosworth models fitted with the Borg Warner T5 gearbox.

This kit combines our Wilwood clutch master cylinder conversion, T5 concentric hydraulic clutch conversion and the hydraulic fitting kit, providing the components required to convert the clutch operation from the pedal through to the gearbox.

An excellent upgrade for road, fast road and competition cars, particularly those fitted with heavy-duty clutch covers or paddle clutches, where the original clutch operation can become heavy and unpleasant to use.

The hydraulic conversion provides a much smoother, more controlled clutch action and completely removes the original T5 clutch fork and release mechanism.

Kit Includes

Pedal & Master Cylinder Kit

• Wilwood clutch master cylinder
• Wilwood fluid reservoir
• Aluminium reservoir mounting bracket
• Heavy-duty pedal rose joint
• Rose joint spacers
• Stainless steel fittings
• Bulkhead mounting bolts
• Nyloc nuts and washers
• Banjo and hydraulic fittings
• Reservoir mounting screws

T5 Gearbox Concentric Hydraulic Conversion

• CNC machined replacement T5 gearbox nose
• High-quality concentric hydraulic clutch slave cylinder / release bearing
• New front input shaft oil seal
• Stainless steel mounting bolts

Hydraulic Fitting Kit

• Hydraulic inlet fitting
• Hydraulic outlet fitting
• Fittings designed to accept -3AN hose
• 1.5 metre stainless steel braided hydraulic hose

This fitting kit connects the hydraulic system to the concentric slave cylinder and provides the hose required to complete the installation.

CNC Machined T5 Gearbox Nose

The conversion replaces the original Borg Warner T5 gearbox nose with our purpose-made CNC machined hydraulic version.

Manufactured from aerospace-quality aluminium, the replacement nose allows the concentric hydraulic release bearing to be mounted correctly around the gearbox input shaft.

No machining of the gearbox is required.

The original nose is removed and replaced with the supplied CNC machined assembly.

Master Cylinder Installation

Installation of the Wilwood master cylinder requires three holes to be drilled in the bulkhead.

We normally mark the position using a punch and drill using an 8mm drill, although customers have also successfully used a step drill.

The Sierra clutch pedal has a mounting hole approximately 1 inch down from the pedal pivot. This is used for the supplied heavy-duty rose joint.

When positioning the master cylinder, it is extremely important that the centre line of the master cylinder is aligned as closely as possible with the pedal rose joint.

The push rod should operate with little or no angle.

Take your time when positioning the master cylinder before drilling. Measure twice, drill once.

Bulkhead Reinforcement

We strongly recommend bracing or reinforcing the bulkhead when carrying out this conversion.

Sierra bulkheads are known to flex around the clutch mounting area, particularly when heavy-duty clutch covers are being used.

Reinforcing this area gives the master cylinder a much more solid mounting point and improves clutch pedal feel.

Concentric Bearing Clearance

With a standard clutch installation, the T5 conversion normally does not require spacer shims.

However, it is imperative that the release bearing clearance is checked during installation.

There should be approximately 1-2mm free clearance before the release bearing binds against the clutch cover.

Different manufacturers' clutch covers can vary in installed height, so this measurement must always be checked rather than assumed.

If adjustment is required, we also have stainless steel spacer shims available in:

• 1mm
• 2mm
• 3mm
• 4mm

These allow the concentric slave position to be correctly set for different clutch and cover combinations.

Why Convert to Hydraulic?

In our opinion, this is one of the best modifications you can make to a T5-equipped Sierra Cosworth.

The complete hydraulic system provides:

• Significantly improved clutch pedal feel
• Smoother clutch operation
• Better control of heavy-duty clutch covers
• Improved operation with paddle clutches
• Removal of the original clutch fork and release mechanism
• Modern concentric hydraulic release bearing
• More direct and consistent clutch engagement
• Complete master cylinder, hydraulic line and gearbox conversion

It is particularly worthwhile on modified and higher-powered cars where an uprated clutch assembly has made the original clutch operation excessively heavy.

Important Fitting Information

This is a conversion kit and requires mechanical installation, drilling of the bulkhead and careful measurement of the clutch release bearing clearance.

We recommend taking your time during installation and checking all measurements before final assembly.

If you are not confident carrying out the conversion, we recommend having the kit installed by a competent garage or motorsport specialist.