In the archive about the shift on the fly elimination it says:
"Here's the type of vehicle you absolutely need to get the different parts from:

1996, 1997, or 1998 1.6L JAPAN-MADE Suzuki SideKick (read: not CAMI built), with manual transmission. Canadian Trackers and any SideKick with the 1.8 & 2.0 Liter motors will NOT work."

What about older cars? Like 1994 1.6L vitara? With 5.12

Nope.....must be Japanese (Canada-built Zuks have slight differences), and must be 96-98 because of the 26-spline axles.  Also, if your GV is a manual transmission, you will want to get a CV axle from an automatic GV.  The manual transmission Grand Vitara's CV mid-shaft and outer shaft will not mate to the Sidekick inner stub that goes into the carrier.  If you have to, though, you can use a complete 1.8L Sidekick passenger axle, but it will be just a touch shorter than the hybrid axle, so the hybrid is the optimum solution. 

Also, if you're GV is an early automatic (1999-2002, I believe), it'll have an aluminum front axle housing.  You will want to think about replacing with the steel housing from a 5 speed or later automatic (for 2003-05, I think they went to steel housings in the automatics).  I'm sorry to be the bearer of bad news.....good luck, though!

The only part that actually matters is that you get the 96-98 setup. This is because they are 26 spline like your Vitara or Grand. I just found this out on Saturday. I always thought Suzuki changed from 22 to 26 splines up front in 1993, guess I was wrong.

The other important part is you don't NEED to use the hybrid axle. It's alot easier to just get a Sidekick Sport axle, and call it a done deal. No mish-mashing parts together and having a bear of a time trying to find Japanese built Suzukis to harvest parts from. That's how I think anyways.

The other important part is you don't NEED to use the hybrid axle. It's alot easier to just get a Sidekick Sport axle, and call it a done deal.

As Davyboy pointed out, the Sport is a wee bit shorter than the GV, thus increasing the chance of pulling out the CV.  Its bad enough that lifted GVs have a propensity to pull out to begin with.

No mish-mashing parts together and having a bear of a time trying to find Japanese built Suzukis to harvest parts from. That's how I think anyways.

I never had a problem getting the parts, and the assembly is rather easy, compared to the other stuff needed for the SOTF elim.  Easy way to find a Jap-built?  It will say Suzuki on it.    Most of the Trackers came from CAMI.  Might be different in the great white.

Personally, if one doesn't feel comfortable messing with CV's, then the elim is not in their technical range.

Of course, NY has a lot of super cheap pick-n-pulls (can get a full steel front hub2hub for under $100) with lots of GVs now as they are coming off the roads due to rust out.  Might be different elsewhere.  I'm thinking of getting a $150 2.7L w/auto (with my coupon!) for my Sammy right now.

Dang, those are some dirt cheap parts prices. Holy wow!

I was informed that only Sidekicks with the VIN starting with "JS" were Japanese, all the other ones are CAMI.

Of course, NY has a lot of super cheap pick-n-pulls (can get a full steel front hub2hub for under $100) with lots of GVs now as they are coming off the roads due to rust out.  Might be different elsewhere.  I'm thinking of getting a $150 2.7L w/auto (with my coupon!) for my Sammy right now.

That's it I'm calling you.  I need to stop up your way some time   

http://www.zukiworld.com/forum/index.php?topic=21016.0

 

That's it I'm calling you.  I need to stop up your way some time   

We'll meet halfway, the really good place is in Binghamton