Barra Engine Swap

RRS offers a complete Barra engine conversion for your early classic Ford. The engine swap includes engine mounts, specific-fit headers, plug-and-play wiring harness, and flash factory ECU. It also comes with a range of transmission options and gearbox cross-members. Elevate your vintage ride’s performance effortlessly with RRS's all-inclusive Barra engine swap package.

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Matthew explains what it takes to install a Barra into a classic Falcon Fairlane or Mustang.

Feb 12, 2019

RRS Barra Conversions

The first turbo Barra, the 240T, came out late in 2002. Production continued through until its final evolution - the 325T.

Production ceased in September 2016. The power numbers, the reliability, and the availability of the Barra convinced RRS that this engine swap was going to be big.

In late 2015, RRS began building a Barra-powered 1984 Ford LTD to check possible clearance and compatibility issues of the RRS coil overs, rack and pinion steering kit, the under-dash brake booster, and the 3-link rear suspension system.

In building the LTD, RRS was able to develop a series of products that would help Barra swappers put these awesome engines in classic 60s, 70s, and 80s Fords and Mercurys. This page showcases the products RRS developed and the solutions we found along the way.

Typhoon Conversion Products

Putting a Barra or FG Turbo motor into a classic Ford was the No. 1 engine conversion in Australia in 2019.

RRS has finished the LTD build and completed engineering. A modified car can be used as a daily driver on full registration.

The Barra or FG motor, with turbo in it's stock location is 730mm wide. It will fit into most Falcon/Fairlane engine bays (not XK to XP Falcon), but only just. In the RRS LTD, the turbo (in stock position) cleared the drivers side shock tower by 4mm.

Your first choice is modify the engine or the engine bay, our choice (RRS) was create a lot more space and therefore a lot more air movement.

Replacing the original front suspension with Gen7 front coil overs allowed RRS to "notch the shock towers" without reducing the structural integrity of the front of the car.

Typhoon Notching Kit

Maverick, early US Falcon and XK to XP Falcon have some of the narrowest engine bays. By notching the shock towers, you can increase room and more importantly airflow. Turbos thrive on cool air.

Notching the towers meant installing the HO2 height adjustable coil-overs and an RRS brake package.

H.O. 2

Gen7 H.O.2 RRS latest coil-over with geometric correction knuckle, high load Bearing Hub, light weight billet top mount, cold formed chrome silicon wire springs.

Typhoon Engine Mounts

RRS developed the Barra Grabber Engine Mounts for Barra/FG turbo motors. The Grabber engine mounts are designed to sit on V8 frame mounts (as pictured below). RRS has developed a series of engine mounts and gearbox mounts to fit the turbo 4.0L motors to Falcons, Fairlanes, Mustangs, etc.

Typhoon Sway Bar

The RRS Barra Sway bar, which measures 24mm, navigates the sump.

Typhoon Pedal Mount

You need to use the electronic accelerator with your motor. RRS has developed a simple universal flat plate pedal mount in 2 configurations: BA or FG.

Typhoon ZF Gearbox Mount

RRS gearbox mount cross member, the highlighted piece is if you incorporate the RRS 3-link rear suspension system into the mod motor conversion.

G6 GT Rack n Pinion Powered Rack

The Barra motor has power steering pump on the motor, making upgrading to the RRS rack and pinion system so simple. The latest RRS fast ratio bolt-in powered rack, comes with a 5-year warranty.

RRS has models to suit Australian Falcons, Fairlanes, Fairmonts, and LTDs, a great range of left and right-hand drives for Mustangs, Mavericks, Torinos, US Falcons and Fairlanes and the Mercury Cougars, Comets, Cyclones, and Montegos

RRS engineer and product designer Matthew Pankau moved the battery to the boot. "Moving the battery to the boot is a bigger change than people think 18 kilos moved from in front of the front wheel to behind the back wheel".

Stealth SS - Under Dash Brake Booster

RRS has developed the Stealth under dash brake booster and master cylinder (manual or auto left or right-hand drive).

Trans-Am 3 Link

RRS has created the Trans-Am 3-Link rear suspension mini coil-over system to suit 9" diffs. If you purchase the 3-link, you will get the gearbox mount cross member included.

The 3-link will allow the use of the RRS wheel speed sensor.

The RRS Trans Am 3-link is a great way to complete the conversion of your classic Ford into a high-performance, totally reliable ride that starts every time. It will also essentially be a climate controlled work of engineering perfection.

Speed Sensor Kit

Depending on your configuration, you may need to install an aftermarket speed sensor. Pictured here is a simple rear wheel sensor that easily mounts in the RRS 3 link setup.

As RRS went through the build, we:

modified the trans tunnel to fit the ZF gearbox
built an unrestricted dump pipe
created A dual exhaust system
had a stand-alone loom built
built a speed interface to work with the original digital 84 LTD dash display
modified the sump to fit the cross-member
changed the dip stick position
put in A new hi-flow fuel sender in the tank
modified the front lower radiator support panel to accommodate the radiator hose.

These products were too specific for the combination of 270T, ZF gearbox, and 84 LTD to make into products, but they may help with your build.

Front Sump & Pick Up

To fit a Barra to an X-series Falcon or early Mustang you will need a front sump and pick up, you can either modify your sump and pick up or use the sump from a territory to clear factory X member

The Falcon, Fairlane and early Mustang have a cross member that sits across the centre of the engine bay. The Barra of FG (except Territory) are rear sump and even the territory sump does not clear all cross members

Remapping the EMC & AMC depending on the choice of gearbox.

The Barra and FG motors are fully integrated into the car, body control module, ABS, ACM (for auto models), traction control, speed sensors, all these functions need to be hooked up, disabled or mimicked, when you take the engine out the original car.

There are many different ways to solve the wiring, at RRS we choose to fully convert the computer and loom to a stand alone function and use the ZF 6 speed automatic ACM.

The advantage with the stand alone system is the ability to use existing your dash and customise the car setup with multiple computer tunes.

In the years since RRS started the Barra conversion many wiring and computer remapping options have been developed. A google search will give you many options.

In Sydney there is a loom builder called JB Automotive Electrical.

4" Dump Pipe

Turbos love air and air flow the original exhaust on the FG is restricted 2¼" dump pipe RRS configured a dump pipe to an open 4" system to navigate past the RRS rack.

Twin 2½" Exhaust

RRS has developed 4" single collector to a twin 2½" exhaust to high flow muffler for the long wheel base LTD. There are now many after market pipe kits both engine and exhaust.

The lower radiator support panel needed to modified to allow the use of the Barra radiators and fans.

Applications

XK-XP Falcon

You might be building XL with a big block, an XM ute with Barra power, or an XP station wagon with a Boss 290, RRS can help you build a fully street-legal, one-of-a-kind classic early Aussie Falcon.

Our performance products and engine swap packages will give your early Falcon the precise handling, comfort and reliability you would expect from a modern vehicle.

XR-XY Falcon

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your early Falcon the precise handling, comfort and reliability you expect from a modern vehicle.

An XS Aluminator (Coyote race series) into an XY, or a Barra-powered XT ute, or maybe a blown 429 into XR, RRS can help you build a fully street legal, one-of-a-kind classic. The RRS height adjustable bolt in coil overs or powered rack will transform your Falcon, call or email RRS for a quote.

XA-XC Falcon

Coil-over front and rear suspension, rack & pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your early Falcon the precise handling, comfort and reliability you expect from a modern vehicle.

A Boss 290 5.4L into an XB coupe as above, or a Barra-powered XC wagon, or an old school 351 into XA, RRS can help you build a fully street-legal, one-of-a-kind classic. The RRS height adjustable bolt in coil-overs, a powered rack, and a 3-link rear, one or all will transform your Falcon. Call or email RRS for a quote

XD-XH Falcon

Are you building an X series with a big block, Barra power, or Boss 290? RRS can help you build a fully street-legal, tracking-eating beast. The RRS height adjustable bolt in coil overs will transform your Falcon. Call or email RRS for a quote.

Compact Fairlane FB FC FD

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Compact Fairlane the precise handling, comfort and reliability you expect from a modern vehicle.

Whether you’re looking to build a Compact with a Barra turbo 6 motor or an old school N/A small block, daily driver, street and strip sleeper, RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable bolt-on coil-overs or powered rack will transform your Compact Fairlane. Call or email RRS for a quote.

ZA, ZB, ZC, ZD Fairlane High Performance Parts

ZA-ZD Fairlane

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your early Fairlane the precise handling, comfort and reliability you expect from a modern vehicle.

ZA to ZD Fairlanes can be transformed into anything, show winner, rat rod, daily driver, Sunday cruiser. RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable, bolt-in, coil-overs, a powered rack, and a traction-grabbing 3-link, one or all, will transform your Fairlane.

ZF, ZG, ZH Fairlane High Performance Parts

ZF-ZH Fairlane

You could build a ZF 351 cruiser, or maybe a Barra-powered Marquis drag-racing sleeper. RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable, bolt-in, coil-overs, a powered rack, and a traction-grabbing 3-link, one or all, will transform your Fairlane.

ZJ, ZK, ZL Fairlane High Performance Parts

ZJ-ZL Fairlane

You could build a Barra-powered ZJ (LTD), or maybe a big block 429 Cobra jet into ZK. RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable, bolt-in, coil-overs, a powered rack, and a traction-grabbing 3-link, one or all, will transform your Fairlane.

64½-66 Mustang

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your early Mustang the precise handling, comfort and reliability you expect from a modern vehicle.

RRS’s advanced technology and engineering, combined with your own unique choices in the gearbox, engine, wheel, differential etc. will assist you in building a street-legal, show-winning, track-eating beast!

67-68 Mustang

69-70 Mustang

71-73 Mustang

Whether you’re looking to upgrade with an XS Aluminator (Coyote race series), or a twin-turbo small block, RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable bolt-on coil-overs or powered rack will transform your Mustang,

60-65 US Falcon

66-70 US Falcon

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Falcon the precise handling, comfort and reliability you expect from a modern vehicle.

Whether it’s an XS Aluminator (Coyote race series), or a twin-turbo small block, daily driver, street and strip sleeper, RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your classic Falcon.

62-65 US Fairlane

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Fairlane the precise handling, comfort and reliability you expect from a modern vehicle.

Whether it’s a Coyote motor with performance headers or a big block daily driver with a rat rod, RRS can help you build a one-of-a-kind classic that is fully street legal. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your classic Fairlane.

66-70 US Fairlane

RRS can help you build a fully street-legal one-of-a-kind classic, whether it’s a Fairlane with an XS Aluminator (Coyote race series) or a twin-turbo small block. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your classic Fairlane.

70-77 Maverick

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Maverick the precise handling, comfort and reliability you expect from a modern vehicle.

RRS can help you build a one-of-a-kind classic that is fully street-legal, whether you’re looking to upgrade your Maverick with an XS Aluminator (Coyote race series) or a twin small block, or are looking to turn it into a daily driver or street and strip sleeper. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your Maverick.

66-70 Torino

Coil-over front and rear suspension, rack and pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Torino the precise handling, comfort and reliability you expect from a modern vehicle.

Whether you are looking to create a daily driver, weekend cruiser, or show car, RRS can help you build a one-of-a-kind classic that is fully street-legal. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your classic Torino.

66-70 Ranchero

The GT rack and pinion steering kit RRS manufactures for the 66-70 Ranchero are built for you and your requirements. RRS will custom-build your coil-over suspension to suit your engine, your gearbox and your wheel choice.

No two builds are the same. Your car is a unique combination of motor, gearbox, differential, and battery location. RRS takes these factors and the car's use (street, track, or show) into consideration when configuring your suspension and braking.

RRS's superior suspension, steering and braking reduces bump steer, eliminates roll understeer, increases traction, and decreases braking distance. RRS can help you build a street-legal, show-winning, track-eating beast.

All RRS 66-70 Ranchero high-performance parts are VSB14 compliant and approved for use in all states and territories.

RRS 66-70 Ranchero upgrade kits require no fabrication.

60-65 Comet

60-65 Mercury Comet the forgotten classic, RRS has been building rack & pinion bolt on steering systems for these iconic under valued cars since 2001. The first generation Mercury Comet has a unique stub axle and is one of only three models the RRS coilovers require a rack first. RRS has evolved the product range for the Comet over the last fifteen years, the rack & pinion is generation 5 and the IFS is generation 7.

If you are restomoding your Comet, the best steering upgrade you will find is the GT5 bolt on rack & pinion, the best independent front suspension system is the RRS G7 coil-overs. If you want to put coyote motor with decent headers, the easiest way is notch the towers to get space where you need it.

Customize your 66-69 Mercury Comet build with RRS superior performance products.

66-69 Comet

Coil-over front & rear suspension, rack & pinion steering, drum-to-disc braking upgrades, and engine bay expansion will give your Comet the precise handling, comfort and reliability you expect from a modern vehicle.

No two builds are the same!

An XS Aluminator (Coyote race series), or a twin-turbo small block, daily driver, street and strip sleeper, RRS can help you build a fully street-legal one-of-a-kind classic. The RRS height adjustable bolt-on IFS coil-overs or powered rack will transform your classic Comet.

71-77 Comet

71-77 Comet owners upgrade now!

Pro: Compact lightweight car Con: Tiny engine bay, not many bolt-on suspension or steering products available. RRS can take away the cons, RRS has engine bay expansion, bolt-on rack & pinion, bolt-on coilover front suspension, drum-to-disc upgrades front and rear, and a complete rear suspension including a 9" diff bolt-on system. Comet owners

68-71 Mercury Montego Bolt-in performance parts

68-71 Montego

68-71 Mercury Montego high-performance parts. The GT rack and pinion steering kit RRS manufactures for 68-71 Mercury Montego are built for you & to your requirements. RRS will custom-build your coil-over suspension to suit your engine, your gearbox & your wheel choice. No two builds are the same, your car is a unique combination of motor, gearbox, differential, & battery location. RRS take these factors & the car's use (street, track, show) when configuring your suspension & braking.

RRS's superior suspension, steering & braking reduce bump steer, eliminate roll under steer, increase traction, and decrease braking distance. RRS can help you build a street-legal, show-winning, track-eating beast.

67-70 Cougar

Mercury Cougar was labelled as "Untamed elegance" What a classic...

With RRS suspension, steering, and braking upgrades you can transform your classic Cougar into a modern handling sports pro-tourer. Make your Cougar the envy of all, IFS, rack & pinion, 3link, 4 wheel disc brakes, with no welding, no fabrication.

No two builds are the same!

A 68 Mercury Cougar with a coyote motor, performance headers, coilover suspension & rack pinion steering the ultimate pro-tourer. Or a 1969 Cougar with a 3.5L V6 turbo and a 10-speed auto from the latest F150 notched towers and an RRS IFS