Ford developed the car around the chassis and mechanicals of its predecessor, the Sierra Cosworth to accommodate the larger Cosworth engine and transmission, whilst clothing it in Escort body panels to make it resemble the standard Mk V. Designed under the guidance of Rod Mansfield and John Wheeler of Ford's SVO department, the styling was carried out during 1989, by Stephen Harper at MGA Developments in Coventry. The body tooling was created by coachbuilders Karmann at their facility in Rheine, Germany, where the cars were manufactured.
Changes were made to the engine management system and a new turbocharger was fitted. Permanent four wheel drive with a 34/66% front/rear split came courtesy of an uprated five speed gearbox as used in the Sierra Cosworth. Recaro sports seats came as a standard fitment. Later production models were available without the oversize tail spoiler although by far the majority were still ordered with it. Like its Sierra predecessor, they are commonly nicknamed "Cossie" by enthusiasts.[1]
The Escort Cosworth was a rare car, with 7,145 vehicles produced from the start of production on 19 February 1992 until the last car rolled out of the factory on 12 January 1996. A tiny number were unofficially imported to the United States, where it was considered one of the greatest performance Fords of all time.
Two versions were produced. The initial 2500 units were "homologation specials" used to get the FIA accreditation for entry into the World Rally Championship. They were fitted with a Garrett T3/T04B turbocharger. Among these initial units, a handful were badged as Motorsport versions, these lacked certain refinements such as a sunroof and sound deadening. The second generation, starting production from late 1994, were fitted with a Garrett T25 turbocharger, a smaller unit which reduced turbo lag and increased usability in everyday driving situations. With these later models, the 'whale tail' spoiler became a delete option.
The Escort Cosworth was the first mass production car to produce downforce at the front. (45NM at 70 MPH)
Motorsport
The car was to be Ford's new rally car, and very successful it became with its total victories amounting to 8 in Group A guise. Drivers included famous victor at the 1994 Monte Carlo Rally, the Frenchman François Delecour, future quadruple World Rally Champion Tommi Makinen (who took his maiden event victory for Ford in Finland that same year before departing for Mitsubishi for 1995), as well as the Belgian Bruno Thiry and, from 1996, 1990 and 1992 World Rally Champion Carlos Sainz of Spain. One-time 1988 and 1989 back-to-back title-winning force for Lancia, Miki Biasion and 1991 Rally Catalunya winner Armin Schwarz were among the other fabled pilots to be seen behind the wheel.After modifications were made to the car to make it a World Rally Car for the 1997 and 1998 seasons, it went on to score two more victories for the Ford Motor Company Rally Team, now based in Cumbria and being run by Malcolm Wilson's M-Sport. With Thiry, Ari Vatanen (on a one-off podium-scoring basis at the Safari Rally after Thiry suffered an injury) and four-time World Rally Champion Juha Kankkunen now behind the wheel of the cars, the Escort name finally bowed out of works rallying altogether after a double-podium at the season-ending 1998 Rally of Great Britain.
The Escort RS Cosworth was produced until early in 1996 when the European Union introduced a new set of noise regulations for motor vehicles and Ford decided to stop production rather than change the car to meet the new noise regulations. Despite this, the now-modified RS Cosworth was used by Ford as their factory rally car until it was permanently replaced by the Focus WRC for the Monte Carlo Rally of 1999.
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