Outer Limits 4x4 Board

There is a fair bit on the UK sites about Vits smashing the front diff housing when goin at it hard. I have just installed a frt/rear air locker set and was wondering if I need to do some more work in the front housing area .. Has anybody had experiences with this ? I did notice my rh rear axle shaft is twisted approx 1.5 mm on the spline as well. It hasnt broke yet but I have been giving it some !! Heard of broken rear axles ?? thks Dick

Dick wrote:There is a fair bit on the UK sites about Vits smashing the front diff housing when goin at it hard. I have just installed a frt/rear air locker set and was wondering if I need to do some more work in the front housing area .. Has anybody had experiences with this ? I did notice my rh rear axle shaft is twisted approx 1.5 mm on the spline as well. It hasnt broke yet but I have been giving it some !! Heard of broken rear axles ?? thks Dick

Antt had one but he did his on a rock - smashed the outer casing.

No question they are not as strong as the rear Vitara or even the front Sierra, but what you have to remember is with the internet it now only takes on and you have a "worldwide manufacturing flaw".

Vitara rears have a reputation of being pretty damn bulletproof.

The guys in the UK who keep breaking the fronts are running big tyres (33") on Calmini Super articulation 3" suspension lift - also usually front locker or LSD (which I don't have).

This is probably related. I've watched some of their movies and seen them snap in conditions that I have repeatedly exceeded using 30" and 31" muddies.

Of course I don't have the locker or their front travel (with 2" suspension lift).

There's a few theories that the Calmini kit allows too much axle movement so the driveshafts can come out too far allowing load on unstable parts of the housing, and also that the alloy front diff centre is weaker than the sierra steel one.

There's also the levels of body flex stock vitara frames get putting additional load on the alloy axles as a sideways brace.

As far as I know no one has yet been able to conclusively prove that it's A, B or C.... they are all interrelated Im sure.

The front diffs being alloy are weak and do break.The only option is a solid swap.
I run a welded. rear in the buggy with the 37's I have only broken one rear axle.
SAM

Do you not have the steel axle in front of the GV V6? What model did that get introduced?

yep, smashed my bottom front diff mount when i very first got it

i took it to a local tig guru, who rewelded it all and strengthened it up heaps. the stock mounts are a piece of crap, no meat around the bolt holes whatsoever.

if you have the steel diff, shouldn't have as many worries

overkill wrote:The front diffs being alloy are weak and do break.The only option is a solid swap.
I run a welded. rear in the buggy with the 37's I have only broken one rear axle.
SAM

Is there a known engineering point at which you can say.... you're running 3X" rubber or X" suspension lift - you'll break the front diff if you go up another inch?

I know this varies based on the driver skill, driver attitude and the conditions, but is there any reasonable guideline or are there too many varied conditions of failure?

There's no question they are not as strong as say the Sierra front axle, but what I'm looking for is some sort of pattern, and some point at which it's "enter at own risk".

As I pointed out, most of the guys breaking front axles regularly in the UK have got a known factor involved - the Calmini 3" suspension kit. Is there any other known factors that are responsible for this breakage?

I think there are too many variations of failure to come up with a system but i would say lockers would be a start and 30 plus tyres.I think gearing would help as it would allow a lot more gentle approach.
SAM

I think I'd rather put a Solid Front axle in than use a "gentle" approach.....



Seriously though, as I've gone up from 26" through to 31" inch my approach has become far more gentle since I don't have the clearance issues.

When I first got the Vitara I had to basically bounce my way throught everything to keep up and I'm really suprised how little permanent damage I did considering that approach....

Going up higher than 31" tyres I think there's better mods to first - lower gearing would be of more benefit to both me and the Vitara at this stage than another inch or two of rubber.

Probably would have been true at 30" too....

I'm not 100% sure about this - but i believe there is a fellow in the suzuki club down here that is fitting the 3rd member from a sierra to his vitara estate wagon front diff - which he has blown out two times (he's running some 32" centipede's on it)...

Perhaps just replacing the weak point (i.e. the alloy housing) may be the easiest option?

The steel fronts are in the manual GV's and XL7's and from this year also in the autos. Front air lockers should help reduce the risk of breakage. Lowering your gearing may also help as you won't need to attack with the same speed reducing the chance of a spinning wheel suddenly getting traction and sending the load through the front axle causing breakages. Some have also installed Warn fusible hubs to let go first.

Phew! this one has created some interest ! thks for the info.. I have just installed the front locker and was thinking it may help since I should be able to go more "gentle" and prevent all the spinning I used to get. Chopped my Cooper ST's to bits last time I was at LC Park !
I did notice my model has a 4 bolt rh mount and the UK pics had only 3 bolt.. Must of been a change.. I will also add another mount to the pinion housing, this sounds like a good idea to support the twist when you reverse hard.

if anyone does break one i have a complete spare front end sitting under my house - from hub to hub

and also an air con compressor and condensor

while on this topic.....does the center out of a vit rear fit a sierra rear?and do they break?

mud4b wrote:while on this topic.....does the center out of a vit rear fit a sierra rear?and do they break?

The rear centre isn't the problem.

do you know if it fits the sierra diff?

mud4b wrote:do you know if it fits the sierra diff?

Nope the Vit crown wheel is bigger (same 27 spline axles though)

The Great Gonzo wrote:if anyone does break one i have a complete spare front end sitting under my house - from hub to hub

and also an air con compressor and condensor

Could be interested in the a/c. Is it complete and how much?

not a complete setup - just the compressor and condensor and a fe hoses plus an airbox

if you want it make a (decent) offer

Does anyone know if the 3.73 Sierra Ring and Pinion will fit in the Vitara rear centre....

Don't see any reason why not..... but I'd like to know while I'm doin gthe shopping.