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Exploded front diff

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Offline brlj

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  • 6" Lift w/ 33x12.50 TSL Radials, Exoskeleton
    • Bills 93 Tracker
Re: Exploded front diff
« Reply #15 on: July 18, 2005, 05:12:39 PM »
Why do I need a machined sammy center section? Or is that if I put in a locker?

Yeah if you want to run a lockrite in the front the sammy carrier needs to be machined so your right side cv stub fits into it.

Bill
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Offline Digger

  • 1991
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  • 1996 Suzuki X-90 4X4
Re: Exploded front diff
« Reply #16 on: July 18, 2005, 08:43:24 PM »
Cool, so I don't need that right now.

For right now until I scrounge up the pieces, Goblin's fixed and Silver's up on jack stands and 2wd. Depending on how long it takes me to gather the parts, I might just pull Silver's cv's out and strap the drive shaft up out of the way. It can drive to the frame shop in 2wd...
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline HotRod

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Re: Exploded front diff
« Reply #17 on: July 18, 2005, 09:56:10 PM »
This is what I know.
Quote
BTW. The Sammies rear center section has 4 spider gears where the kicks only have 2.
And since youll be running the 5:12s, you'll also need the pin can thingie that holds the spider gears pins in. (5:12s are too small to hold the pins in)
Cuase, If you broke yours, the spider gears will be bent ever so slightly and cause problems later.
It's hard to tell but learning by my freinds mistake. He's had to replace his front gears more than once to discover that problem.
Really.
If your not running a Locker or something. The rear Sammie center section 4-spider gears are Stronger than the Kicks 2-pin spider gears.
I haven't broken mine yet but my 2dr is down for an engine rebuild. Smokes too much for me.
And we all know, Smoking is Baaaad. ;) ;D
« Last Edit: July 18, 2005, 09:58:45 PM by HotRod »
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95 2dr Geo Tracker with Calmini 6"inch combo lift, 32'inch BFGs M/Tlocked and loaded--D.D is my 06 Racy RED Aerio SX AWD
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Offline Digger

  • 1991
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  • Gender: Male
  • 1996 Suzuki X-90 4X4
Re: Exploded front diff
« Reply #18 on: July 18, 2005, 10:14:36 PM »
Actually, I trashed the R&P when it went, so I wasn't planning on re-using anything out of the broken housing...

I was just going to get a whole new set of internals, side gears and all...
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline lil_Truck

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Re: Exploded front diff
« Reply #19 on: July 19, 2005, 08:15:21 AM »
All you have to do is get a complete steel front housing unit for an XL-7 from the junk yard.  It will have the housing, center section (thrid member) and axil shaft.

Then all you need to do is change the R&P and your good to go.


Note:  I had no problem removeing and installing my Anvil (completly assembled) into the truck with the front steering attached.

Good luck.
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e-mail: liltruck|removethispart|@comcast.net
96 Tracker
6" Calimini Lift with custom Frame
32 MTR's Warn 8000i
Front/Rear ARB's Many New Mods soon.
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Offline Digger

  • 1991
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  • 1996 Suzuki X-90 4X4
Re: Exploded front diff
« Reply #20 on: July 19, 2005, 09:57:55 AM »
Actually, I just got back from the junkyard and they had an auto 2003 XL7 with 5.13 R&P. If I grabbed that front rear and the right cv shaft, it should bolt in and give me full steel housing, the correct R&P as well as 26 spline shafts, right? Do the CV's from an XL7 fit the Tracker?
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline Gear

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Re: Exploded front diff
« Reply #21 on: July 19, 2005, 02:07:52 PM »
Quote from: Digger on July 19, 2005, 09:57:55 AM
Actually, I just got back from the junkyard and they had an auto 2003 XL7 with 5.13 R&P. If I grabbed that front rear and the right cv shaft, it should bolt in and give me full steel housing, the correct R&P as well as 26 spline shafts, right? Do the CV's from an XL7 fit the Tracker?

you'll need to grab the aircompressor too and wire it up so that the diff will work.
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Jeff
'03 Grand Vitara & '89 SWB Vitara
Blue bits, Locked bits, Missing bits
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Offline Twan013

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Re: Exploded front diff
« Reply #22 on: July 22, 2005, 07:18:26 PM »
what commonly causes the front diff to go kablooey?  is it from smashing into stuff, or a lead foot?  i plan on running 31 inch tires on my tracker, in not so hardcore terrain... little to no rockcrawling, no jumps (like some i've seen)... basically just trail riding, with some mud and creek crossings... i'm trying to figure out if given the kind of driving i'll be doing, if i need to go ahead and replace all that stuff, or wait to see if it breaks...  any advice from those who have experienced this?
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Offline wildgoody

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Re: Exploded front diff
« Reply #23 on: July 22, 2005, 08:13:58 PM »
Twan, if you drive like that, just wait,
I have yet to break a diff, just keep the bolts
tight on the side of the diff, this is where they
can twist and break too

Wild
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Real Trucks Are Built, Not Bought,
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Offline Mikerpm4x4

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Re: Exploded front diff
« Reply #24 on: July 22, 2005, 08:41:52 PM »
The Xl7 shafts are longer that trackers. You could swap the inner cup off the Xl7 to get a 26 spline for the pass side. The carrier should be swapped also as the XL7 uses an air line to activate 4wd. It would just be easier to use the tracker one.

Mike
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The_Dude

Re: Exploded front diff
« Reply #25 on: July 23, 2005, 02:19:28 AM »
There are some pics of the XL7 front housing in this article;
http://www.zukiworld.com/month_090103/feature_sidekickdrivetrainimprovements.htm
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Offline Digger

  • 1991
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  • 1996 Suzuki X-90 4X4
Re: Exploded front diff
« Reply #26 on: July 23, 2005, 07:28:47 PM »
I looked at the exploded diagram at the junkyard for the XL7's front diff and it didn't show any airline or fitting... I didn't see anything that wasn't in the diagram for the Tracker... Ok, so I need a 99 and up GV complete housing(Diff housing and pinion snout housing), 5.12 R&P to add into that and side gears/right cv/left stub axle from a 96 and up tracker... right?

Sheesh... this is getting complicated! All I want is both steel housing pieces, the right ratio and 26 spline sidegears/shafts. Is this too much to ask??!? LOL! ::) ??? ;D
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline jagular7

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Re: Exploded front diff
« Reply #27 on: July 24, 2005, 06:57:53 PM »
From my understanding of Zukipilot's front axle setup is he used a 3rd member (drop out center section) from a XL7, a set of 5.83 gears for a Trackick, a modified Sami case with the EZ locker. He used the Trackick long side inner axle as he used the Anvil for the steel axle housing. The Sami case is altered to accept the larger 26-spline side gears for the 26-spline shafts.
While I was at the melt, I compared my XL7 inner long axle to a Trackick and I recall it being ~1/2" longer. The cv flange was exactly the same though (the driver's 3 point cv mounting flange).

Good luck.
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Lenexa, KS
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Offline Digger

  • 1991
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  • 1996 Suzuki X-90 4X4
Re: Exploded front diff
« Reply #28 on: July 25, 2005, 11:48:56 AM »
Ok, one thing that might help me is to get the right terminology applied to the right pieces. From the pics on Calmini's site, the anvil is just the front long portion of the housing. What is the actual correct name for the rear-most piece of housing that the pinion snout comes out of? That's the piece I recently broke. From closer inspection, it appears that the crack started right at the pinion snout's mounting ear, then progressed all the way around the snout housing until it completely separated the pinion from the ring gear.

I recognize the need to reinforce this area to keep this from happening again. After reading Jagular's post above, it seems as if the snout housing and the drop-out third member are separate pieces and this is getting me confused. According to that post, Zig is running an anvil, XL7 third member, 5.83 Track/kick gears, a modified sammi case(machined to fit the 26 spline side gears), an ez locker and a Track/kick long side inner axle... I was under the impression that the pinion snout housing had the carrier for the whole differential molded into it. Is this right or wrong?

Like I've stated before, what I'd like to end up with is the following:

Full steel outer case(axle housing as well as pinion snout housing)
26 spline side gears/shafts
5.12/5.13 R&P(are these actually the same or are there actually the 2 different ratios?)
And I want this to be able to bolt in without too much modification(but I plan on adding a snout collar of some kind to reinforce the snout mount).

So what pieces do I need? The entire case set from a 99 and up Grand Vitara, right?

Are there any Grand Vitaras that came with the 5.12/5.13 R&P? If so, wouldn't that bolt right in and give me everything I want? (as long as I snag the entire front diff assembly along with the right(passenger side) cv and left(driver's side) long inner axle shaft? Or would I need the entire front diff assembly as stated above from a 99 and up GV and the right side cv from a 96 and up track kick for the right length?
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Had a cool sig pic till I changed the text... sigh...
90 Tracker: "Silver", 2" BL, 1-1/2" Coil Spacers, Strut mount flip, Calmini Header, Winch, 31" Swamper radials, Sold.
98 Suzuki X-90: Calmini 2" Sus, 1-1/4" whl spcrs, 2" Exhaust, Cobra Safari Bar, Neon, Sold.
96 Suzuki X-90: Mostly stock daily driver(for now)
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Offline Gear

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Re: Exploded front diff
« Reply #29 on: July 25, 2005, 08:31:16 PM »
what i did for my vitara/tracker was take a entire front diff assembly from a GV replace the center with an arb airlocker, use the vitara long inner axle (the one with the trangle on the end) and use the vitara's 5.125 R/P.  this gives me a steel frontend.
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Jeff
'03 Grand Vitara & '89 SWB Vitara
Blue bits, Locked bits, Missing bits
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