Wow 

Thanks very much for the write up nprecon!

GO FOR IT!!
I used a Calmi donor. It was too difficult to find a Japanesse donor. For the front diff, I swapped out the WHOLE diff, just had to put on the stock Vit/Track brackets to hold the front of the diff. Way easier, no real reason to swap the pot's.
I could not find out the reason for not using the Calmi diffs. The write up refers to swapping out the Side/Track third member into the Vit/Track pot, which may have been the original problem. Since I kept the unit as a whole, its been fine.

Otherwise, stock hubs are great. Try to get a second set in case there's a seized one.

Since your down there you should beef up the cross member mount. In the link below at the end you can see how a steel strap is bent over the rear of the front diff, definetly needed if you have an aluminium housing. http://www.zukiworld.com/month_020103/feature_frontendupgradeswithhagen.htm

If you have the steel housing. I would STONGLY suggest that you don't worry about the Calmi issue, pull the ring and pinion and have that put into your steel third and pot.

FYI, your stock rear diff's housing (can) for the spider gears should be the same as a sammie's (easy way to check, is to call about ordering a ratcheting locker). Keep this housing/can, as it is needed if you ever want to put a ratchetting locker in the front. Refer to the link to check what I mean.

Mine has been great for over 2 years. Presently I've just busted the Cursed Aluminium housing that holds the pinion (search 'busted front diff' to get an idea of how weak it is). I must now get a new front diff and try to find a steel Vitatra diff to put the Ring and Pinion In (and locker  ).

Now why did this have to come up when I already have my front diff sitting on the floor of my garage? I'd sure like to regear and have a locker in the front. You guys are gonna piss off my wife!

A new steel axle housing from Suzuki for $168???!!  Wow!.  I don't have any Suzuki dealers in my area.  Sucks!!

Did I miss something? Where do you see new steel housings for $168? I can't find a used one for that around here!

Yeah, I know right? In the article (in the link from JayInBarrie) they picked up a new housing from Suzuki for $168.  Even 10 years ago that would have been a steal!  Inflation I guess.

GO FOR IT!!
I used a Calmi donor. It was too difficult to find a Japanesse donor. For the front diff, I swapped out the WHOLE diff, just had to put on the stock Vit/Track brackets to hold the front of the diff. Way easier, no real reason to swap the pot's.
I could not find out the reason for not using the Calmi diffs. The write up refers to swapping out the Side/Track third member into the Vit/Track pot, which may have been the original problem. Since I kept the unit as a whole, its been fine.

Sorry to bring this back from the dead, but i'm very intrigued by your success with a CAMI vehicle.

I'm guessing the rear wasn't a problem, just swap the third members and your done?

For the front, after swapping the entire diff (the pot and the third) and using the stock mounting bracket; were you able to use the stock axles?? What did you do to eliminate the SOTF; just plug the air line?

Anyone? 

Quote from: JayInBarrie on April 25, 2011, 06:24:42 PM

GO FOR IT!!
I used a Calmi donor. It was too difficult to find a Japanesse donor.

Sorry to bring this back from the dead, but i'm very intrigued by your success with a CAMI vehicle.....; were you able to use the stock axles?? What did you do to eliminate the SOTF; just plug the air line?

Sorry about the late reply. It is the season to be outside, not surfing the net.  

The Cami stuff's been working fine.
You still have to make a hybrid axle like the article say's, as one of the stubs into the diff is longer to compensate for the stupid air diaphram.
Yes, just plug up the air line. When the air pump hits 6 psi your 4x4 light comes 'on' on the dash.
Here's some old pics from Suzican 2009
http://s305.photobucket.com/albums/nn204/jayinbarrie/SuziCan09/
Here's Zookpower, you may have to join to see some of the pics.
http://www.zookpower.ca/forums/forumdisplay.php?14-Suzican

I used the rear third from a 98 sidekick sport and the entire front from a 2003 xl7. Not sure where the sidekick sport was made, i am canadian. The front needed 2 mounting holes drilled in order to use one of the centre brackets from my original diff. Apparently 2003 was a changeover year from aluminum to steel diffs... I ordered it and was kinda disapointed when it arrived made of aluminum but it seems to be holding together well. Looks beefier than than the original.

Well, I wheeled around all summer on my stock aluminum diff with the stock 4.62's and sure enough on my last trip I guess I drove it a little too hard and snapped the darn housing.

I can no longer procrastinate, I gotta do a swap.

So far, the best deal I've found is a pair of diffs ( front and rear) out an '02 Tracker with 4.88's. The guy wants $900(Can) for them before tax! Is that reasonable??? Cause to me that sounds like a lot for a bunch of old metal.

My girlfriend, who wasn't very impressed when I broke the housing is even less impressed now that I'm proposing we spend a thousand bucks repairing the truck. Are there any other solutions to this problem that might be a little easier on the wallet?

Anyone have any suggestions 

Update:

Just found a donor vehicle! A '97 Sidekick with 5.13's. I can get the front and the rear assemblies for $400!

Hopefully i can do like JayInBarrie and just swap the whole front assembly (diff and axle housing) and use the stock Vitara mounting brackets.

Wish me luck! 

Kick ass deal! Good luck!

Kick ass deal! Good luck!

Thanks! I'm a little nervous about the job, I've installed a few lift kits in my day but I've never tackled a job that involved swapping entire front clip!

If anyone out there knows of any reason why the stuff out a '97 4 door automatic sidekick wouldn't work, please let me know now before i drive the 400kms this weekend and spend all my hard earned money. 

Its always hard to spend hard earned money.  I think you will be happy with your upgrades, and have a sense of pride in building your own rig how you want it. I need to do more research before I do any large swaps like this.