I talked to Myron of Zukes off road about a locker on the front of my kick. He told me I could use a 1510 Protrax but will need a alignment block to hold in the pins plus precisely drill two holes for the second locker pin. I own a machine shop so the holes will not be a big deal but I have no idea what a alignment block is. I have two rear and one front Samuri 3rd members to grab some parts from.

Is there a tutorial or article on adding lockers to the 95 Sidekick? And what is a alignment block?

Maybe the best person to ask that question is Myron.

Personally I've never heard of a "Protrax" locker, but there is a LockRight 1510 made by a company called PowerTrax, the notes I have from years gone by suggest that the 1510 is intended for a Samurai.



The image above is the front differential of a Sidekick, the one below is the Samurai.



Find items 15~19 in the lower image and compare them to the equivalent parts in the upper image.

#15 is the differential pinion, there are four in the Samurai diff but only two in the Sidekick - that is the big difference - a four pinion diff requires the block #19 to hold the short cross pins #18 in place - this is what I think Myron may be calling an alignment block (Suzuki calls it a "JOINT, DIFF PINION SHAFT) - so you would have to fabricate a similar block to hold the inner ends of the cross pins, and drill two holes in the case for the outer ends.

If you're also planning on installing a locker in the rear, when you take it apart compare it to the front - the rear is a four pinion similar to that of the Samurai.

Two points - first - since you have Samurai diffs on hand, I believe it may be possible to install the locker in the Samurai diff and put the assembly into the Sidekick, and the second, and perhaps more important point - Sidekick aluminum axles are not that strong, they break when used with a locker.

The ZOR website shows a listing to buy a front carrier with a locker installed and all modifications made to make it work.  The price isn’t too bad if you have a core to send them.  If you check YouTube there is a video that walks thru the steps of installing a locker in the front.