ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: jayheats on April 01, 2019, 08:27:06 AM
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I'm new to the forum and this is my first trackick build. I have owned a couple in the past, but this is the first I will be doing a build on. I have seen a few Zuki SXS builds and decided I was going to give it a go. I just bought this 1997 Geo Tracker 4 door / manual clutch for $700.
Current plans are;
3in lift and 31's
Cut out fenders
Cut the top and do a roll bar
Half Doors
Hagen Widening Mod
3 rows of seats for a total of 7 seats.
It should be a fun project and a lot more affordable than a new SXS. Here we go!
(https://beta-static.photobucket.com/images/ad210/Jayheats/0/b8b7b5cc-6d3e-4e2c-8c1f-f3864b9c04f7-original.jpg?width=1920&height=1080&fit=bounds) (https://beta.photobucket.com/u/Jayheats/p/b8b7b5cc-6d3e-4e2c-8c1f-f3864b9c04f7)
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Welcome! I look forward to your build...
-Eric
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I'm still hunting down parts and wanted to track some of my findings here.
I'm looking to upgrade to a steel housing.
I have a 1997 Geo Tracker (4 door) 1.6L MPFI 16V SOHC 5 speed man. with 5.125 gears.
From reading Eric Bewley's posts I found that I can get a steel differential from a Grand Vitara or XL7, but I'm having a hard time finding one with the same gear ratio.
I did find that these years have the correct gear ratio;
99-03 Tracker 1.6L MPFI 16V SOHC Auto or manual 5.125
99-03 Vitara 1.6L MPFI 16V SOHC Auto or manual 5.125
Should I draw the conclusion that ANY "Manual" Grand Vitara or Tracker 99-03 will be a direct bolt-in with the same gearing? Crossing my fingers :)
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The Steel diff won't have the same Gear ratio. You'll have to put your r&p out of the aluminum into the steel housing.
-Eric
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Finally started to make progress on my project.. cleaned up the oil pan and painted it.
- Installed the new parts;
oil down tube o-ring
dip stick o-ring
oil filter
water pump
crank seal
oil pump seal
new thermostat
timing belt
timing belt pulley
Dizzy o-ring small and large
serpentine belts
valve cover gasket
air filter
Next I think I'll adjust the lifters!
(https://hosting.photobucket.com/images/ad210/Jayheats/0/900043af-1ec3-460f-9976-33e60352250c-original.jpg?width=1920&height=1080&fit=bounds) (https://beta.photobucket.com/u/Jayheats/p/900043af-1ec3-460f-9976-33e60352250c)
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Finally got my 16v Timing finished last night.
This diagram shows setting both the Crank and Cam to TDC and setting the dizzy to #4
(https://i.imgur.com/nVorwvO.jpg)
Here is the actual dizzy set to #4
(https://i.imgur.com/7F4XUQE.jpg)
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2000 Chevy Tracker 4cyl 500ppi (for the front springs). 1997 Honda Accord 149ppi (for the Rear springs). 2in Differential Drop bracket, 1/2in Driveline spacer, Idler arm Brace, 31x10.50R15 Mudders, and 2in rear upper control arm spacer.
(https://i.imgur.com/UOZQAo9.jpg)
Rear Lift springs installed
(https://i.imgur.com/hLZ9JVb.jpg)
I might try some 2003 Jeep Liberty 6cyl 383ppi (for the Front Springs) if these Chevy tracker ones don't lift it enough.
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Got the 2in Differential Drop installed last night. This is Bob Tuppers Kit. I had to grind off a rib on the bottom of the 3rd member to make it fit. There is definitely a bolt sequence to installing.
(https://i.imgur.com/GzZPVCy.jpg)
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Wow I like the finding the coils at a yard. What struts are you using?
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Wow I like the finding the coils at a yard. What struts are you using?
I’m going to be installing the Buick Regal struts this week. But also going to try to do a 1in reverse strut spacer on top
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One step closer to the Hagen Widening mod. Two extra flanges welded on the long shaft and the short shaft got cut on the line and welded to the third flange.
Three extra axle flanges
(https://imgur.com/862S1Oc.jpg)
Cut on the line if doing the Hagen Widening mod
(https://imgur.com/9qHAsvT.jpg)
Welded and ready for install
(https://imgur.com/E168xIh.jpg)
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Following the instructions, I flattened out the edge and drew a straight level line to the outer edge. I measured over 1 inch from the original hole (which is about half way) and drilled the front hole. After that put the a-arm in place, put the bolt in front, and then rested the A-arm on a block of wood. Then I put red paint on the end of the other bolt and put it in the rear hole. The red paint marked the spot I would need to drill. Drilling is finished and I'm ready to weld the washers on.
(https://i.imgur.com/izfGdqZ.jpg)
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Washers are welded into place and painted with rustoleum.
(https://imgur.com/T0ebsW7.jpg)
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Reverse strut spacer.. when your regal struts are too long... so you take up an inch with a reverse strut spacer that goes on top.. I ended up slice the top of the rubber lip off the lower strut spacer. It spaces the strut up about 1.15 inches.
(https://imgur.com/53LletT.jpg)
I put some washers in there and installed the strut. Very firm fitment. Using the regal strut you have to drill out the large top Main washer to fit over the new regal strut threads.
(https://imgur.com/VbBUlHP.jpg)
The strut shaft fits into the lower strut mount with the metal sleeve removed.. helping keep things centered. I like how the lower strut mount plugs the hole with the bottom of the rubber mount, keeping dirt out.
(https://imgur.com/cPhrabF.jpg)
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I was getting my reverse strut spacer modification all tightened down and then I realized I had forgot to put in an important washer. This Large washer must be included (it is not simply a washer to secure the dust boot - on the original setup). It actually holds the strut from pushing up and ripping out the upper rubber strut mount.
(https://i.imgur.com/bexb54a.jpg)
In the above picture you can see that I cut the rubber lip off the top of the lower strut mount.
(https://i.imgur.com/Th8yj44.jpg)
After the Large washer is in place, put the upper strut mount on and tighten it back up.
(https://i.imgur.com/VbBUlHP.jpg)
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Coil Nut Spacer Mod
I used 2000 Chevy Tracker 4cyl front coils on my 1997 Geo Tracker. Using coils that lift the front, you will notice the control arm spring perch becomes a worse angle. Combined with the Hagen widening mod, my lower spring perch needed some re-adjusting. I used a couple of nuts to create a solid spacer and then welded it to the control arm.
(https://i.imgur.com/78RcFQH.jpg)
I put the nut spacer right next to the control arm drain hole to make sure the placement was exact on both sides.
(https://i.imgur.com/cI1uqkj.jpg)
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Hagen Widening Mod Follow-up
After doing the Hagen Widening Mod, I noticed my bump stop towers was touching the springs!
(https://i.imgur.com/2aALzgz.jpg)
Using a cutting wheel I cut 3/4 of the way around the tower and used a hammer and jack to close the gap on one side, then I welded it.
(https://i.imgur.com/rG5fF5e.jpg)
Closing the bump stop tower gap.
(https://i.imgur.com/NGkfTLA.jpg)
After the tower has been welded and painted I tried putting the spring back in place and put the control arm under weight. Now the tower doesn't touch!
(https://i.imgur.com/lDlWMp2.jpg)
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Finally have my rig back on all 4 wheels..
So I still have strut adjusting and steering caster to do, but I was able to roll it out of the garage finally after a month of working on it off and on.
(https://i.imgur.com/NLtxIHW.jpg)
(https://i.imgur.com/GcOc0wT.jpg)
I'm making progress but still have a ways to go.
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Lifted Geo Tracker with 2003 Jeep Liberty (6cyl) Front Springs and 97 accord rear springs. Just trying on a different spring setup. I was thinking the jeep coils would be stiffer, but they are actually softer than the 2000 Vitara coils I had on there previously.
(https://i.imgur.com/ZPhmQPz.jpg)
(https://i.imgur.com/JtEvIOm.jpg)
I wonder if this angle is going to kill my CV's. Time to do a droop test.
(https://i.imgur.com/mHFODw2.jpg)
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Your sidekick looks awesome. I wonder if the front springs had something to do with linear vs progressive coils? They definitely feel differently offroad.
I wouldn't have guessed the jeep coils were softer or lighter rated. That's awesome it worked well for ya.
Do your springs bow out at all? Or are they straight in the perch?
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Your sidekick looks awesome. I wonder if the front springs had something to do with linear vs progressive coils? They definitely feel differently offroad.
I wouldn't have guessed the jeep coils were softer or lighter rated. That's awesome it worked well for ya.
Do your springs bow out at all? Or are they straight in the perch?
Thanks! The Jeep Liberty coils are rated at 383ppi vs the stock geo springs at 500ppi, I still need to do an offroad test to see if they bottom out too easily.. The springs bow a little bit, but not much with the welded nut spacer I put in there. I will need to cut and weld the towers again because the bowed spring is barely touching again and makes a rubbing sound. More details to come this week. I will also confirm the cv angles are going to work.
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Nice build! You are going a similar direction as I am, CHEAP! I have the 4 cyl Gen 2 Tracker springs on the front of my rig. I am parting out an 03 XL7, so I am going to try those springs. I have a front bumper I built on it, but I am wanting to build another that will be heavier, so I am thinking I may need the heavier rate XL7 springs.
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Since I added the liberty springs, I decided to put a little more curve on the front bump stops.
(https://imgur.com/udeEwPC.jpg)
(https://imgur.com/Zf2DgDv.jpg)
(https://imgur.com/P0ppvJh.jpg)
(https://imgur.com/2Ge6R0T.jpg)
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Here is a better picture of the nut spacer in place
(https://imgur.com/Je1Ho5x.jpg)
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The more I play with the front end suspension, the more I realize you shouldn't try to push the limit with coil height. These Jeep Liberty coils are lifting it more than 3in.
3 inches should be the max you go for when lifting with coils due to cv angles. Once you try 4in lift coils or any higher you will have a hard time rotating the arm to set the spring into the groove.
So I cut one half coil off the springs and the result was the same lift height. I think this has something to do with where the cut coil ends rest on top. I went out to test the cv angle and flex. No binding and good flex!
I think I'll cut another half coil off and see how much that drops it.
My goal for fender height is 35.0in in Front and 35.5 in the back. My current Measurements are 35.75in in Front and 34.25 in the back.
(https://i.imgur.com/6rnVL6Q.jpg)
(https://i.imgur.com/CywqptF.jpg)
Looks Like I need to do some trimming on the back.
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Looks good. We have cut the lower spring pads and angled them to help reduce some of that bend when at ride height.
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I had my front end apart working on the alignment for the forth time adjusting the regal top slot holes... I noticed that when I turned the wheel hard it actually pushed on the passenger CV, the steering became stiffer, and the diff moved 3/16in. So I cut off the flange from the stubby and sliced off a little more and re-welded... problem solved. In the end I had to grind the head of one of the bolts for clearance. Nothing like doing a job twice..
(https://i.imgur.com/nd3RdIQ.jpg)
(https://i.imgur.com/vGNTXMP.jpg)
(https://i.imgur.com/qxIqUq6.jpg)
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I had my front end apart working on the alignment for the forth time adjusting the regal top slot holes... I noticed that when I turned the wheel hard it actually pushed on the passenger CV, the steering became stiffer, and the diff moved 3/16in. So I cut off the flange from the stubby and sliced off a little more and re-welded... problem solved. In the end I had to grind the head of one of the bolts for clearance. Nothing like doing a job twice..
I switched to using round headed bolts with a hex head. :D
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Some other front springs to try might be Ranger or Trailblazer front ones. I have heard good things about that.
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Some other front springs to try might be Ranger or Trailblazer front ones. I have heard good things about that.
I have heard bad things about ranger coils, like they are too large of an opening and don't seat right.
Besides, I absolutely love these liberty coils on the front of this tracker. They ride so soft and are perfect for wheeling.
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Nice build. I love the look of 31s on these. Mine also a 4door 5spd and I'm currently running 30s. Have you driven it yet on the 31s? How does it do?
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How's this build going