I broke my front housing by ripping it apart. Bought a complete cast steel housing to replace it. Wanted to just bolt my aluminum 3rd to the front of the housing and be done with it. No. Had a problem with chipped teeth from the pinion and ring gear.
Bought another XL7 automatic complete housing. When I removed the 3rd, the ring gear looked great. So no problem. Yah, right. Took it apart tonight. Ring gear is fine. Had inked the gear before removal. The pinion is way off from being 'in' mating with the ring gear. My replacement gear is now also messed up. The pinion has several edges chipped away. Pics coming.
I certainly hope the yard takes this mess back.

Looks like I'll have to order a 'new' gear set from the dealer.  My gear guy thought the backlash was way too tall, like 0.0025". Should be 0.0007 to 0.0012". It appears that Suzuki didn't hire the proper gear guy for assembly....

Unless someone here knows where to get a good set for under/near $350.

Here are some close-ups of the pinion teeth.

are XL7 gears different than the older trackers? Couldnt you use an older carrier? I can buy 5.12s for about 100 bucks from most wrecking yards.

Mike

That is what I was thinking. However, since the carrier is a pressure locked carrier, I would have to swap over to the Sami carrier, with locker and mod'd side gears to work with my axles (~$400). If I can get these new gears installed into the cast steel housing, I'll be at the 'Melt. I just wanted to get things back to somewhat normal.
I have a long side inner axle, and a bad gear set to play with at the Melt. I'll take measurements of the brand new R&P as well. Anyone have a digital micrometer they could bring?

I know Zukipilot used the XL7 3rd cast steel housing onto the anvil, with the mod'd Sami locker & carrier and 5.83's.

Before I got my XL7 5.13 new-dealer gears installed, I was told to only measure the outside diameter of the ring. The pinion is matched to it. The ring gear size for the front axle 3rd member is 7" with a simple tape measure.

If the ring gear for the Trackick is 7" also, I can't see why those can't be used in the housing. I would hather a wild hair a$$ guess that the GV and Vitara models front ring gear is also 7" in diameter.