Outer Limits 4x4 Board

ok guys, i'm doing a sas in june, and have just ordered trailtough gearing for my vitara, so i have to get rid of the slipyokes on the transfer.

i was playing around with the spare transfer i have today and got some pics and have some questions.

this first pic shows the rear output shaft, i assume i have to drill a hole in it, then thread it to accept a bolt. anyone have a size for the bolt i should use and size of drill bit needed to tap a thread for this bolt?


now, this next pic shows what i thought might be possible to do. using a sierra/samuri flange, just slip it on the shaft and bolt it on. the problem i have is this flange is off a very early sammy (when they had the 1litre) motor, so it doesnt go onto the shaft. does anyone know if the later flanges slide straight on?

the other problem i see with this is that when the flange slides on further, the bolts to hold the tailshaft in, will foul on the transfer case (this is the bit i've circled)...what can i do to get around this???? ???


this final pic is a pic of the slipyoke cut in half. another idea i had was to get a plate welded to this (obviously i'd cut it square first) then turned down in a lathe, and the holes drilled for the tailshaft bolts. is this a stupid idea or what?




any idea's you guys who have done it, or seen it done could give me would be appreciated, as i dont know if i'm going about this all the wrong way or what ???

cut the splined part off the end of your tailshaft, machine up a flange and weld it to it, then bolt the whole thing to the output shaft using the tapped hole you talked about. same as doing a mog pinion conversion. there will be no load on that bolt, so don't go overboard with it.. M10x30mm or something..
using part of the original shaft means that seal will still work perfect too.

not a bad idea carlton, but the prob is have a look at the second pic, i need to keep the flange away from the tcase housing in some way

think I have a spare tcase flange from a later model if you want it Antt. No good to me

Wt and sj80 sierra flanges are the same as the vitara flanges

Antt give me a call and i'll give you a more indeph idea of whats needed for the conversion

antt wrote:not a bad idea carlton, but the prob is have a look at the second pic, i need to keep the flange away from the tcase housing in some way

make a new flange to weld to the remains of the slip joint. 8mm plate or something, it will be well clear of everything..

does that stone shield or whatever it is come off the shaft easy enough? that thing will make it hard to get in and get a good weld in there..

Antt, have a look on Zukiworld. Pics are up of a completed SYE.

heres a pic off Zukiworld too.

cheers cj and sikid. looks like you were right carlton. he's done it in exactly the same way that you said, and it seems to work and clear everything

antt wrote:looks like you were right carlton. he's done it in exactly the same way that you said, and it seems to work and clear everything

same method, different application.