Outer Limits 4x4 Board

Hi Team,

I’m interested in seeing some people’s trickiness for fitting an AW4 (Vitara 4-speed Auto) into their sierras.

This gearbox seems to be the best option (not easiest) as far as semi-bomb-proof automatics go with an Overdrive gear. It also can be run stand alone, is readily available (both in parts and tech knowledge and support), has a removable bell housing, has a cable shift mechanism etc.

To narrow down the masses of information you are about to reply with – here are some specifics about what I am after:
1. AW4 only – not trimatic (vitara 3 sp auto) or 5 sp manual
2. Gearbox only – not interested in fitting the vitara x-fer
3. SWB – so I’m not moving the x-fer (much)
4. Divorsed – prefer to keep the x-fer separate

Has anyone got photos UNDERNIETH (!!!) of the Steve Azzopardi coiler? Apparently this car ran an AW4.

One more question – I heard talk that the Output shaft at the back of the gearbox of the AW4 that came behind a J20 (2L vitara) might be different to the standard AW4 that came in the 1.6L models. Can anyone confirm this please?

Thanks,
Greg

Pad

Gwagensteve wrote:Pad

same amount of tech as your usual posts, but due to less ranting, takes much less of my time to read.

My wife has the camera with her, I'll post some later.

i'll leave the electrical side out of it for now. first thing is it will need a tunnel masage. if you don't have a body lift it will require more. don't be shy as the more clearence you have around the auto the better airflow you will get, this makes it much better for cabin heat as these things do generate a bucket load more heat. i always fab up a new crossmember that is un-boltable, this also sorts out the front shaft hitting issues. depending on how you want the t/bar to look will depend on how much you cut away on the tunnel top. i use the vit console so it looks factory, but this does require a fair bit of cutting and welding of a new mount for the t/bar. i'm in the process of doing one and will be getting the new tunnel mount laser cut and folded so all that has to be done is a simple cut and re-weld. if your keen greg let me know and i'll get an extra made for you to try. you will need an out-put support and i always mount off the bottom case holes for the crossmember, not the support bracket. you might have to run a small twin uni shaft but this won't be a problem if you make a simple bracket that ties t/case into auto to stop them fighting each other to some degree. and yes, some of the autos from the larger motors may have a different shaft but i'm yet to see one. i know they do have a different shaft out of the t/case, but this won't affect what your doing.

if you are interested in seeing the vehicle i'm doing at the moment and want to know more about the wiring side just pm me and we might be able to arrange a look.





excuse the dust!.....

Joe will be more help than me, as I didn't build this Sierra. Here are a couple of pictures...

Looks like I better attend to a couple of oil leaks





Can do some more if want anything in particular. Joe's offer sounds the best way to go.

WRX Zook - what are you using there as your bearing support plate? is that the start of the vitara x-fer case cut down? If so - it's quite neat.


Joe - sorry - a little bit confused - are you saying that you make the whole tunnel, or just the piece that sits between the existing sierra tunnel and the vitara centre console?


And here I was thinking this was an unusual and difficult swap

nah, not the whole tunnel...just the mount for the t/bar so it sits properly on the tunnel and can be used with the vit console.

[quote="greg"]WRX Zook - what are you using there as your bearing support plate? is that the start of the vitara x-fer case cut down? If so - it's quite neat.

This was Steve Azzopardi's Sierra. I just talked with him and he can only remember that bearing support plate had to be machined to house the bearing and couldn't recall if it was part of the transfer case or not (done about 7 years ago).