I know the XL-7's front axle housing is almost identical to my '96 TracKick's front axle housing (except that it's steel) and can be bolted in. I also know that the Grand Vitara's 3rd member will bolt into the XL-7's housing and has the same mounting brackets as the TracKick, making the XL-7 housing/GV 3rd the natural upgrade to the TracKick's weak aluminum front axle housing.

I've located a complete '02 Grand Vitara front axle assembly (steel) for $100. I'm buying it for the 3rd but would like to know if the housing is the same as the XL-7 housing?

Both of the housings XL7 and GV are the same as far as mounting and overall dimensions, they're just in steel instead of aluminum. The third member on a manual transimission equipped GV is steel as well and is a direct replacement for your Sidekick/Tracker. From what you've found, I think you could bolt it in as one unit with no mixing and matching required. The XL7 third member is similar but has a thicker "snout" and is mounted a bit differently (it is better). To make it work in your Sidekick/Tracker, you need to get the mount from the third member to the cross member from the XL7 and then you can bolt that whole assembly in.

Hope that helps.

-Eric

It does Eric. Thank you... alot. But I do have a couple of clarification questions.

You said the 3rd on the manual GV was steel. Should I assume that means the auto GV version is aluminum? Also, are the housings from auto equipped XL7/GV steel or aluminum?

Thanks for the info on the XL-7 3rd mount. I'll squirrel that in to my "future mods" file.

It does Eric. Thank you... alot. But I do have a couple of clarification questions.

You said the 3rd on the manual GV was steel. Should I assume that means the auto GV version is aluminum? Also, are the housings from auto equipped XL7/GV steel or aluminum?

Thanks for the info on the XL-7 3rd mount. I'll squirrel that in to my "future mods" file.

Auto GV = Aluminum
Manual GV = Steel
Early Auto XL7 (pre 2003)= Aluminum
Late Auto XL7 (post 2003)= Steel
Manual XL7 = Steel

2003 is a crossover year and I've seen both steel and aluminum in the autos.

-Eric

Thanks for the info Eric. 

i will confirm with Eric, the front diff i pulled out of my 2002 auto xl7 was aluminum, 5.12 gears.

Now that we got that taken care of, what models had the 5.12:1 gear ratio ?

I couldn't find a steel diff in my town so I ordered one from the US which I was told came out of a 2003 auto XL7. It is aluminum.  So either it was not from a 2003 or maybe Suzuki had some leftovers from 2002 which ended up in 03's. I guess you can't beat finding one local and give it a magnet test. The different mounting system does seem better though.

i know this thread is old, but if you get a steel housing from a gv-or xl-7, with the mount, it bolts in and the stock kick cv's fit in or do you have to use the gv or xl cv's?
matt

You can just use the steel housing, but then you don't get to take advantage of the larger axles.

I'm in the boat of "I destroyed the aluminum third member" (at least it was at a toys for tots event) and need to start calling junkyards. So my question is what do I ask for when I call? a 2004 or newer xl7, any year gv or xl7 with manual trans?

So a 2007 xl7 front diff and 3rd member will bolt directly into a 1995 sidekick? All I need to grab is the 3rd member mount, axles, diff housing and 3rd member?


I want a front locker and 32s so I need a steel housing swap. Any help would be appreciated

No - you need the axle housing and third member from an 03 or earlier XL-7 and swap your diff center over to the new third - if not you'll have to fiddle with the CV axles to get it to work.

No - you need the axle housing and third member from an 03 or earlier XL-7 and swap your diff center over to the new third - if not you'll have to fiddle with the CV axles to get it to work.

Auto GV = Aluminum
Manual GV = Steel
Early Auto XL7 (pre 2003)= Aluminum
Late Auto XL7 (post 2003)= Steel
Manual XL7 = Steel

2003 is a crossover year and I've seen both steel and aluminum in the autos.


I thought that the steel was the upgrade tho. I need a steel front diff swap

If you haven't already discovered it, you soon will, internet forums are sometimes filled with misinformation - I'll present what I have, you can accept it or treat it with scepticism as you choose.

The XL-7 was introduced in 2001 as a "stretched" Grand Vitara, and from the front it was indistinguishable from it's smaller engined sibling - apart from engine size, the differences were mostly aft the firewall.  From 2001 to 2003, the XL-7 used a front axle of similar style to that used on all the Sidekick, Vitara, Grand Vitara & Tracker models that preceded it.  From 2004 to 2006, the XL-7 used a completely different front axle design, and from 2007 to the end of production, the XL7 was a completely different GM based product, that did not sell well.

The 04~06 axle looks like this...


This does not have the traditional cast housing with axle tubes, into which the diff is assembled (salisbury style) or the third member fitted (banjo style) - the diff housing is split vertically and bolted together "sandwiching" the diff in between the two, and the axle tubes are then bolted on.

I'm not going to tell you it can't be fitted to your 95, I will tell you it's not the unit that people use for the steel front end swap.

The axle you have now looks like this ...


The axle you're looking for looks like this ...


Notice the difference in the third member mount - this was used from 02 onwards, make sure you get the matching fittings to bolt it to the cross member and it should bolt in.

You may be able to resolve your doubts by calling LowRangeOffRoad - they list the steel housing on their webpage - it'll cost you a grand, but it'll stop you from buying junk that won't fit.