Outer Limits 4x4 Board

Posted: **Fri Mar 06, 2009 7:19 am**

Sorry to see that Bendev.
That reminds me, must check whether my diffs are alloy or steel...

I have a front steel bash plate from Fordy1 which would have prevented that, I hope.

Posted: **Fri Mar 06, 2009 7:40 am**

99% that was torque not impact. It was bound to happen eventually.

That's an alloy housing. Time for a manual V6 GV or XL-7 steel housing methinks.

Posted: **Fri Mar 06, 2009 8:30 am**

Bloody Hell Batman you did a good job on that.

Posted: **Fri Mar 06, 2009 9:02 am**

Have to agree with Gwagensteve looks like torque not impact.

Do you have a front diff locker?

I know you have drop brackets and you got about 31/2 to 4inch lift right.

Not 100% sure but the angle of the cv can put strain on the diff housing, if at too much angle.

I have the drop brackets (Calmini 3” lift) on my Vit but my front diff is lower.

The bash plate on mine has saved it from damage.

Posted: **Fri Mar 06, 2009 9:35 am**

FUBAR

Posted: **Fri Mar 06, 2009 9:55 am**

Dayam, that's some big vent holes in the diff now...

Posted: **Fri Mar 06, 2009 11:12 am**

hey everyone,
There was no impact on the diff, I was trying to climb this hill where I had no traction because i was crossed up. You know what I mean, All the weight on the rear left and front right. Anyway as i was just sitting there bouncing spinning the wheels trying to get out of where I was, I heard this god all mighty crack and that was it, Diff gone.

Today I've found me a metal one, Yeeee Haa (in Power Barne commercial accent) and I'm on my way to pick it up now. The diff. I took out had 39 teeth and 8 teeth so I believe the ratio is a 4.875:1. Anyway hears a some photos of what was left of the diff I tool out or the car.

Posted: **Fri Mar 06, 2009 11:21 am**

top job thats one fcuked diff, I imagine mine doing the same thing!!

how much did you pay for the steel housing? PM me if you want.

Posted: **Fri Mar 06, 2009 11:30 am**

yes thats a great trophy for the wall of shame

Grazza you have a steel diff housing so you will be fine.

Posted: **Fri Mar 06, 2009 12:24 pm**

So did you manage to drive home? I imagine you could still drive with manual hubs, or remove the hub centre thingo.

Posted: **Fri Mar 06, 2009 1:21 pm**

Sorry to hear and see ya diff problems bendev.
What hill climb is that it looks familiar?

Posted: **Fri Mar 06, 2009 1:32 pm**

Jeezus. That is bloody impressive!!!!!!

You must've really been sinking the boot in when it went bang

Posted: **Fri Mar 06, 2009 1:39 pm**

Just read throught the whole thread, great build up.
Have always liked this model

And yes ouch for the last page

@ atari4x4 bet your looking harder for one now lol!

Chop

Posted: **Fri Mar 06, 2009 7:51 pm**

I was looking at the build pics and the tension that the dif drop put on it combined with the power and hopping caused a stress failure.If you look at the pic off the center cross member mount,at the angle sitting on the bushing,after the build, then look at the angle after it broke you'll see the pinion returned to its original position.Thats a lot of strain on a cast housing combined with some heat from working hard.Solid steel axle housing is the way to go.

Posted: **Fri Mar 06, 2009 7:57 pm**

Looking at the CV axle on the passenger side,you mite want to check it out real good before reinstall.

After seeing that, im thinking a toyota solid axle swap for my GV mite be some thing worth looking into.Good luck.

Posted: **Fri Mar 06, 2009 8:10 pm**

Crap

Might I say you did a damn fine job on it though

Did you get enough stuff shot first?

Awesome to see more Zooks in the mag too

Posted: **Sat Mar 07, 2009 8:50 am**

atari4x4 wrote:top job thats one fcuked diff, I imagine mine doing the same thing!!

how much did you pay for the steel housing? PM me if you want.

Hey atari4x4,
I spoke with the people at Suzi4Wreckers and they great. I paid $360 for everything. I think the break up was $100 for housing and $250 plus $10 for something else. I got the steel one out of the LWB Manual Grand Vitara. I'm working over the week end but as soon as I can I'll take some photos of the new stuff before I put it together and get it in the car.

Posted: **Sat Mar 07, 2009 8:53 am**

grazza wrote:So did you manage to drive home? I imagine you could still drive with manual hubs, or remove the hub centre thingo.

Yeah I drove it home. I simply unlocked the manual hubs and took it out of 4WD. That way the CV shafts didn't turn and the diff. just hang there.
Basically all the oil was drained out in the bush so there was nothing left to leak on the road.

Posted: **Sat Mar 07, 2009 9:01 am**

kottunmewth wrote:Looking at the CV axle on the passenger side,you mite want to check it out real good before reinstall.

After seeing that, im thinking a toyota solid axle swap for my GV mite be some thing worth looking into.Good luck.

Hey I was thinking of getting two new CV shafts while its out (haven't decided yet) but can you please show me which photo and what you think the problem is.

Posted: **Sat Mar 07, 2009 9:04 am**

Squik wrote:Crap Might I say you did a damn fine job on it though
Did you get enough stuff shot first?

Awesome to see more Zooks in the mag too

Yeah all photos to cover the article where shot and it happened at the end when I was just playing around. They took photos of the breakage as well.

Posted: **Sat Mar 07, 2009 7:11 pm**

Hey I was thinking of getting two new CV shafts while its out (haven't decided yet) but can you please show me which photo and what you think the problem is.

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I hope that loaded the image,but one pic showing the pinion and pieces hanging  by pas. side upper support.The end of the CV were the oil seal is if that is buggered up by the broken edge of the axle case the seal mite fail later.Being an 02 ,not sure of mileage ,the CV mite not have been replaced on the life of the vehicle,so just a thought since you rebuilding the front end.You defiantly need new ring and pinion.Be sure to clean up rest of differential parts of all metal shaving.

Posted: **Sat Mar 07, 2009 7:28 pm**

Ive done some research and the design of the front end or the Vitaras and GV are pleged with seal failures on passenger side because there isn't a lot of bearing support.Were the driver side has a long shaft.They have a poly bushing you can get from suzuki dealer that goes on the passenger side that inserts into the dif. end to help keep the end were the passenger side CV inserts into the dif. tight to keep it from wallering out the differential and causing failure of the seal.

http://www.suzuki-forums.com/suzuki-vit ... ntial.html

Here is a link,It'll tell you about it.This site also has a lot of info on that model zuk and there are suzuki mechanics that visit that site I have talked to that will give you real answers to hard questions with out a load of srcap added in.

Posted: **Mon Mar 09, 2009 6:19 pm**

Went down to Suzi4wreckers last Friday and got a metal front diff and center from a manual LWB Grand Vitara. Lets see if I break this one!
Hopefully I should have it together and in the car this Wednesday, I'm just waiting on a new set of diff seals.
Here are some pictures of my new diff.

Posted: **Mon Mar 09, 2009 7:42 pm**

hey the pinion mounts look different on the new one compared to the old one, can it be adapted?

Posted: **Mon Mar 09, 2009 11:16 pm**

atari4x4 wrote:hey the pinion mounts look different on the new one compared to the old one, can it be adapted?

Shit, I didn't notice that. I don't have a day off till Wednesday so I'll have to check it out then. I can't see it being to much trouble. I hope.

Hey, If anyone has seen this problem is it an easy fix.

Posted: **Mon Mar 09, 2009 11:37 pm**

It got the better of me so I went outside and checked it out.
Its all good, different mount but same mounting position.

I took photos

Posted: **Tue Mar 10, 2009 8:32 am**

thats good news for you, i'm running the calmini kit & the pinion mount is like your original one so i'll need one off an early GV.

i'm guessing that might be off an XL~7 or very late GV?

Posted: **Mon Mar 16, 2009 9:21 pm**

See you got the good stuff there bendev,A word of caution for ya.The vertical rubber mount is more flexible on twisting then a horizontal mount is.If you have trouble getting the axle to twist and line up to bolt the 1" drop brackets up ,talk to a machine shop you trust and see if they can drill or cut out the 2 holes were the bracket mounts to the pinion housing to allow the pinion to turn a little bit and let the mount on the cross member to stay straight. so the new cross member support bracket wont be in such a bind.

Well you got your work cut out for ya,good luck with it.

Posted: **Tue Mar 17, 2009 12:25 am**

Firstly, to all on the forum, I'de like to say thank you all for your input and knowledge, especially Fordy1, for taking the time out and giving me a phone call and helping me out.

The front end was sorted out and went together fine, with not that much trouble at all.

As soon as I got it back together I called up some mates and went straight out to the seine of the crime, and what a day we had. Apart from me getting stuck in the mud and letting some water in, the GV went fine.

Check out some photos.

Posted: **Tue Mar 17, 2009 12:31 am**

Outer Limits 4x4 Board

Goodbye Jimny, Hello 02 G/Vitara(FS: Old Susspension)