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ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: beagle..t on June 21, 2015, 07:25:40 AM

Title: 2002 build
Post by: beagle..t on June 21, 2015, 07:25:40 AM
well this is going to be awhile as it takes forever to up load pics (internet sucks where I live) so I will try to post something new on my build  everyday until im  caught up on where it sits today.... and ive done a lot in my eyes to my stock 2002 2dr tracker. So had a 91 that was lifted 2" coil spacers and 2" body lift and sat on 30s and preformed well for what I need and do until an accident wrote the thing off. so on the hunt I went and found a 2002 2 dr for a good price. and this is where it all begins. what I started with
Title: Re: 2002 build
Post by: beagle..t on June 21, 2015, 07:37:34 AM
Well to fund my build and buy coil spacer lift, a body lift, steering  extender, and a new panhard relocation bracket I needed to sell my 91. sold it and bought everything I needed to do the lift and let the transformation begin   
Title: Re: 2002 build
Post by: beagle..t on June 21, 2015, 07:56:40 AM
so started on the install and it went fairly good.so after the lift was in it was time to find some new shoes and here's  what I found and I had to shave 1/8" off calipers for the rims to fit and this is how it sat for about 4 months
Title: Re: 2002 build
Post by: beagle..t on June 21, 2015, 11:06:40 AM
after the 4 months it was time to think about changing gears from 4.88 to 5.12 just because I went wheeling and found this. now I knew I had a problem so went on a hunt for new diff and gear set, and happened to find a full set from a sidekick sport because there CV axles are the same length as the newer tracker/vitara. I got full front end with CV axles and hubs for $240 which I thought was a super deal
Title: Re: 2002 build
Post by: beagle..t on June 21, 2015, 11:11:45 AM
I was very nervous to do this swap as I read all treads on it. it was so bad that some were says yes it will fit and some said that you have to make a new axle, I even called TT and talked with Brent and he gave me confidence that it would work so back to pulling wrenches and getting this done. 
Title: Re: 2002 build
Post by: beagle..t on June 21, 2015, 11:25:07 AM
while this was all done it was about a 1-2 months and went wheeling again and went for a swim and hydro locked the motor (wife very unhappy) so once again hunting for a new 2.0 litre with lower miles and ended up finding one but pricey it was ....$1500 shipped to my door with 163,000 km and back to pulling wrenches again. no pictures it was a straight re-re. and that lasted for acouple more months when my drive shaft decided to shit the bed at 120 km per hour . drive shaft was fubared and a new one was $700 so I found a used one for $150
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 07:23:09 PM
started building a winch bumper. Started like this
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 07:29:16 PM
so people said that the approach angle was no good so I decided to flip the winch plate and extend the frame rails to accommodate the winch
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 07:35:56 PM
so to extend the frame I sleeved the rails like this
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 08:06:06 PM
after I figured that the winch would work best to my application I had to start designing everything around the winch plate.
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 08:12:41 PM
well once I got the front designed I started on the wings. oh ya winch plate is 1/4" plate bent, where the roller fairlead is, its 3/16", and the wings and front skid plate is 10 gauge. So the wings weren't the easiest it started like this a square piece of metal
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 10:32:53 PM
and it ended up like this
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 10:40:22 PM
well after a long design I ended up with this
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 10:47:44 PM
and well after some paint and cut some holes in the skid plate so the rad can breath it ended up on the truck like this
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 10:55:16 PM
well so I got a gun box given to me but it was 54" and that wouldn't fit along the back of the tracker so ...what to do, cut it and weld it to fit so that's what I did. also installed cb and made a mount for antenna last week
Title: Re: 2002 build
Post by: beagle..t on June 27, 2015, 11:06:12 PM
well this weekend I got some lights so decided that well might as well install them so that's what I did welded on some tabs for two lights  and made a bracket to hold the light
Title: Re: 2002 build
Post by: beagle..t on July 18, 2015, 07:30:38 PM
so finally finished sanding of silver paint off rims now its down to bare aluminum and now its ready to plasti-dip the rims.... but needed new tires for my work truck and thought what a great idea to mount the new to me 30" bfg all- terrains on the rims, got a deal for mounting they wanted 20 bucks a tire and got them down to 10 bucks for mount and balance. So tires are now mounted but they used 6 oz of weight to get them true on most of the rims . they figured that the cause was because they are solid rims or slightly bent but they are true now . so now just found out that I can get a deal on paint and now just want to figure out what color, don't want black as rims that are on there now are that color was thinking something unique (blue, purple, green, white, red) 









+6336.-9
Title: Re: 2002 build
Post by: 4x4Johnny on July 19, 2015, 06:28:12 PM
Hey pal. Nice work on this build thread. any feedback on the BFGs? Do you buy it on a local store or online?
Title: Re: 2002 build
Post by: beagle..t on July 20, 2015, 07:28:01 PM
bought them used with 70% left they are now installed on the rims that are ready for plasti-dip
Title: Re: 2002 build
Post by: beagle..t on August 03, 2015, 06:21:22 AM
Well put some 4 dr tracker springs in the front to help with the bum high from the winch and bumper. The 4 dr springs are 5/8"  taller from stock and tracker sits 1"lower in the front. the driver side was easy the problem was passenger side, trying to put springs in with no spring compressor is a PITA 3 hrs of struggling and finally got it in. now it sits closer to level and its close enough for me.
Title: Re: 2002 build
Post by: 4x4Johnny on September 01, 2015, 01:13:21 AM
Hi! may i know what winch brand are you using for your ride?
Title: Re: 2002 build
Post by: beagle..t on September 08, 2015, 04:48:16 PM
smittybuilt 8000# big enough to pull me up a tree. Im eventually will go with synthetic rope and a different fairlead and I think it will shave 20 lbs off for weight as winch weights 94 lbs
Title: Re: 2002 build
Post by: Junk-Yard-John (03-SWB Vitara) on October 14, 2015, 08:35:20 PM
nice rig.  im in progress of a custom 2" spring swap on my 03.
Title: Re: 2002 build
Post by: MEATHEAD on November 03, 2015, 06:11:38 PM
Do you got any plans that you could send me on the bumper you made
Title: Re: 2002 build
Post by: beagle..t on November 04, 2015, 05:46:40 PM
yup I still have the plans for the main part of the winch , I think the wings I don't have I can email them
Title: Re: 2002 build
Post by: beagle..t on February 09, 2016, 08:51:34 PM
well haven't had much to do on my tracker and getting the itch, so I think that I might want to do something different to the mule, and talking with some guys here (BRD HNTR, Fordem). the banker in the household has said that I can buy some up grades for the tracker. Well we all know where this will go, question is what to get locker, transfer case gears, there is a lot of options but the only option that I could think of is ....(thx BRD HNTR) I'm in the process of purchasing a 2001 XL-7 4x4 (pictures to come) the price is in my reach and there really isn't much left to do. So yup going to bite the bullet and swap out my motor that I just put in about a yr ago and paid way to much for, and swap in the 2.7 auto. Project wont start till end of March and hopefully will be done by July fingers crossed. Hey BRD I will be coming down your way in March sometime and will stop by with donor as it has more room for the cargo on the way back so I don't have to drag my trailer with my truck, if your around will PM when it gets closer   
Title: Re: 2002 build
Post by: beagle..t on February 10, 2016, 05:53:11 PM
well just got the ok I will take 900  ;D for my 2001 xl-7, so I guess I will be picking it up Saturday. I guess not to bad considering that it has 268,000 kilometers and its the hole donor that drives. Now I have to get the FSM for both  and a timing chain, water pump,  rear main and valve cover gaskets and im sure there will be some more stuff that I will need but that's where I will start with
Title: Re: 2002 build
Post by: beagle..t on February 20, 2016, 03:21:46 PM
well last Saturday went and picked up the xl-7ran good the valve covers leak and so does the oil pan so that will be changed when I start the motor and wiring swap. Figured that I will change the hole dash I think that it will save me couple hrs  from pulling the wiring harness, I think there is about 12 plugs behind the dash that go to harness and that includes the fuse box. I think that I will use the mirrors and front seats, dash, hood maybe gas tank cause its 2 gallons bigger and anything else that will fit 
Title: Re: 2002 build
Post by: beagle..t on February 20, 2016, 03:23:29 PM
lets try some pics
Title: Re: 2002 build
Post by: BRD HNTR on February 22, 2016, 06:51:50 AM
That was only one "pic".  We will expect lots of pics as this project gets underway.
Title: Re: 2002 build
Post by: beagle..t on February 22, 2016, 07:44:06 PM
I tried to post acouple of motor and interior but wouldn't let me and there will be lots of pics motor removal /install and wiring swap and then when I run into wiring problems then I will invite you for bbq car wiring repair ;)....lol
Title: Re: 2002 build
Post by: beagle..t on February 22, 2016, 07:47:54 PM
interior pics
Title: Re: 2002 build
Post by: beagle..t on March 06, 2016, 06:10:20 PM
well started to take interior out and bumper off so that I can get closer with the cherry picker to remove motor and harness. Also put the drain plugs back in ....forgot about them, I pulled them when I hydro locked the motor couple years ago. So carpet, seats, and plastic is out. was going to pull drive train next weekend by I'm going to be to busy :(   
Title: Re: 2002 build
Post by: beagle..t on March 06, 2016, 06:14:00 PM
oops forgot picture with no front bumper..... I forgot how heavy it is with winch on bet it weighs 160#
Title: Re: 2002 build
Post by: GrumpyVit on March 08, 2016, 03:14:43 PM
Looking good.
I'm starting my swb 1.6l 2002 model Grand Vitara soon, along similar lines to you but going for 29" tyres got std size muds at moment with 32mm wheel spacers.
I'll post some pics in a build thread, with some pics of my Samurai I built around 15 years ago.
Cheers.
Title: Re: 2002 build
Post by: beagle..t on March 20, 2016, 11:38:39 AM
well had some time yesterday so I started pulling everything out. So motor, tranny, TC out dash, steering column and wiring harness out. so all that's left is a few odds and ends in the 2002 then I can start removing; the donor parts. I will post pictures when I can of whats been done
Title: Re: 2002 build
Post by: beagle..t on March 24, 2016, 07:16:27 PM
ok... had some free time so I can post pics of the bare 2002 ...no motor, tranny, TC, dash, steering column, and wiring harness pulled out un-cut   
Title: Re: 2002 build
Post by: beagle..t on March 24, 2016, 07:17:59 PM
engine bay pic
Title: Re: 2002 build
Post by: beagle..t on March 24, 2016, 07:19:23 PM
and the pile of parts
Title: Re: 2002 build
Post by: nprecon on March 26, 2016, 08:05:03 PM
... and a KDX in the background?
Title: Re: 2002 build
Post by: beagle..t on March 26, 2016, 09:26:48 PM
yup  a KDX 200 that's been bored out to 220.....good eye  :laugh:
Title: Re: 2002 build
Post by: beagle..t on March 29, 2016, 07:35:00 PM
well pulled the rest of the parts out that i think that I wont need and ordered a fsm and wiring diagram which should be here by the weekend then getting ready in 2weeks to start swapping everything over. I will be taking lots of pics and labeling everything from the XL-7 so that there is no confusion on my part. It is sure going to be a tight fit but everything will get a degreaser bath and a pressure wash before install so it will be nice and clean.
Title: Re: 2002 build
Post by: beagle..t on April 25, 2016, 06:13:55 PM
well alittle progress started to pull the V6 and tranny w/TC on Saturday... well considering that i pulled the motor and tranny and wiring harness in about 6hrson the 2002  it took 9hrs to pull just motor and tranny, still got the wiring and dash to do. ordering chain and gaskets this week and motor definitely needs a degreaser bath... all I can say is wow alots of wires   
Title: Re: 2002 build
Post by: Tan Zuk on April 25, 2016, 07:38:57 PM
Good to hear things are moving along for you. Degreesing my motor took quite a while it was actually faster pulling the parts off and clean them for me. Figured might as well change out as many gaskets and seals while I was at it. Put in a new oil pump for good measure at the last minute.

Hope it is smooth sailing for you.
Terry
Title: Re: 2002 build
Post by: beagle..t on April 26, 2016, 08:53:19 PM
ya me too smooth is good, but there are always going to be something that will go wrong
Title: Re: 2002 build
Post by: beagle..t on May 08, 2016, 09:23:09 PM
well couple hrs to kill this weekend and started labeling all the wires under hood and under driver side dash so that dash is able to come out. Steering column is out and dash is ready to be removed, via 10 bolts. Man there is a lot of wiring to label, so that the transition over will be easier it justs takes alittle longer  than I expected but I don't want to be in the end and say uhmmmm  ??? where does this go. I keep forgetting camera for pics but will get some in the next day and post the progress
Title: Re: 2002 build
Post by: Tan Zuk on May 09, 2016, 05:22:37 PM
I also spent quite abit of time labling wires when the dash was pulled and the thinning of the harness started. Didn't get rite back at it, finally got back at it and everytime the wires were moved. Yep, the taped labels would fall off, even used a good 3m white electrical tape when marking.

Terry
Title: Re: 2002 build
Post by: beagle..t on May 09, 2016, 08:17:55 PM
dash out and still no pictures  :laugh:
Title: Re: 2002 build
Post by: Tan Zuk on May 11, 2016, 04:35:03 PM
dash out and still no pictures  :laugh:

I kept thinking I was being blocked from viewing your pics for some reason. Now I see you haven't posted any. :laugh:

I find it takes as much time to keep the build thread up to date as it does to do the build at times. You know how the saying goes no pics no work being done. Just alittle motivation. :)

T
Title: Re: 2002 build
Post by: beagle..t on May 11, 2016, 07:55:27 PM
ya I know, the saying is ....pics or it didn't happen :laugh:
Title: Re: 2002 build
Post by: beagle..t on May 17, 2016, 09:23:44 PM
Well haven't had Internet in so long I have to use my phone to post the progress. Well I have completely pulled the wiring harness from the XL from the front to back and have it installed into the 2002. I have taken the fan motor and AC from the XL and that's installed. It took 2days to mark all the wiring that's under the dash and under hood and 2 days to put it back in the 2002. I've swapped the side mirrors and the head lights tail lights,wiper motor. It's a slow process just cause I'm always double checking everything. All that's left is motor work, dash, steering column some odd wiring under dash. I think that I'm going to pull gas tank from XL and install into tracker just that it has 2gallons more and evap canister exhaust and make it fit some how and that's about where I stand at this point in the game of the swap..... I do have pictures and will post them as soon as my Internet is back cause there on my other phone... Starting to see the transformation free m the XL into the tracker as headlights are different and so is the grill so it will be badged in the fronts Suzuki and tracker in the rear till I can fit it and de-badge it all
Title: Re: 2002 build
Post by: Perryd on May 20, 2016, 12:12:37 PM
This build thread is everything I always wanted to do to my 2003 2dr. I've been following it closely and I just wanted to say how inspiring it is and fun to follow. How much lift did you get with the 4door springs over the 2door? I have coil spacers now but my front end is lower than rear. No bumper as of right now.
Title: Re: 2002 build
Post by: beagle..t on May 21, 2016, 05:36:42 AM
Thx I appreciate it, some time you just have to have the courage to jump in and do Ithe motor swap it's not.as bad as I thought but yet the motor and tranny are still look the ground. The  4Dr springs are only 3/4" taller than the 2Dr and with my bumper on it levelled it out. I would say it gave about an 1"lift.   The dash is in and steering column will be in today I hope, I will have to see how my back is feeling.  I have ordered the motorbparts I need and as soon as they get hear I will be installed the timing chain water pump and oil pump and doing the gaskets valve and oil pan  then the fun starts.. I still have no Internet till Thursday so when I do I will be posting some pictures
Title: Re: 2002 build
Post by: BRD HNTR on May 22, 2016, 09:23:45 AM
Thought I would show you my wiring from my phone.  I'll see if it works.
Title: Re: 2002 build
Post by: BRD HNTR on May 22, 2016, 09:28:58 AM
Thought I would show you my wiring from my phone.  I'll see if it works.
I was just using Chrome and logging in.  Let's have some photos now.
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 08:38:10 PM
well yahoo for me :laugh: finally got internet back so I can post some progress pictures... so theses are pics from 2002 tracker dash and steering column out and wiring harness out
Title: Re: 2002 build
Post by: Tan Zuk on May 26, 2016, 08:44:28 PM
Way to go beagle!!
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 08:48:32 PM
more from the donor xl-7 everything but the harness out
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 08:53:28 PM
thx Terry.... more pics heater ac stuff and wiring harness swapped over
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 09:01:26 PM
the new to me seats are just placed in so they come in and out. xl-7 dash bolted in and wiring starting to hook up
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 09:04:48 PM
steering column with tilt steering bolted in.... all xl-7 donor. I don't know how to turn pics right way sry and of course more wiring to hook up
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 09:09:39 PM
it will only allow 1 pic at a time says file to big and I don't know how to fix it. so new hood, folding side mirror, and xl-7 headlights and im using the Suzuki grill
Title: Re: 2002 build
Post by: beagle..t on May 26, 2016, 09:13:51 PM
and the motor still on the engine stand with 2 cans of degreaser on it... will try pressure washing this weekend to clean it up more
Title: Re: 2002 build
Post by: Ridjobradi on May 27, 2016, 05:23:09 AM
This is an ambitious build Beagle.  Thanks for sharing it with everyone. 

I have thought about trying a tilt steering swap in my Sport. 

Sent from my SM-G900V using Tapatalk

Title: Re: 2002 build
Post by: Tan Zuk on May 27, 2016, 05:47:35 AM
it will only allow 1 pic at a time says file to big and I don't know how to fix it. so new hood, folding side mirror, and xl-7 headlights and im using the Suzuki grill


Your MB pic size is set too large on your camera to upload, usually it is 1024mb is the largest. You can try and adjust that setting on the camera or you can download this program called Irfan View. Very simple program to use I have been using it for 15 years for resizing pics.

Terry

Oops forgot the download link

http://download.cnet.com/IrfanView/ (http://download.cnet.com/IrfanView/)

Title: Re: 2002 build
Post by: Perryd on May 27, 2016, 11:07:14 AM
Such an awesome build. I guess taking all the wiring/steering/ECU will make it easier in the long run. Just use the xl7 key and away you go, don't forget to take the door locks lol. Keep up the goodwork!!!
Title: Re: 2002 build
Post by: beagle..t on May 27, 2016, 07:31:54 PM
ya the door locks are on the list. I will try to get the gas tank and the exhaust out this weekend weather dependant as its suppose to rain tomorrow. Swapping very thing I think would be easier, want this swap to be as easy as possible. Rather than trying to thin out the harness I still don't know what will happen with the abs as tracker doesn't have it, I think that I will shrink wrap plug and work on disconnecting the abs light on dash. So far (knock on wood) it hasn't been that bad, better than I expected. My plan is to have it running -90% done by July 1st, as long as driveshaft fits the way I want, and don't have to buy an auto from a 4 dr and get it made too fit. What I really know is I want it done , but I'm picky and precise and everything must look factory so it will take a bit longer 
Title: Re: 2002 build
Post by: Perryd on May 28, 2016, 06:10:52 AM
Are you doing this outside?! True dedication there lol. I don't think it will make a huge difference if the ABS light is on, I don't think I've seen a GM or VW over 6 or 7 years old without it on honestly. If there is a problem detected in the circut it just goes to conventional. I'd just pop the bulb out, but I'm not as picky as you.
Title: Re: 2002 build
Post by: beagle..t on May 28, 2016, 07:44:17 AM
just some stuff easier when swapping stuff from one to the other, I just put them nose to nose ...pull this from donor put this in tracker but motor pulling happens on a cement floor. but it has been nice here so I don't mind working in the sun 
Title: Re: 2002 build
Post by: fordem on May 28, 2016, 12:06:41 PM
I don't think it will make a huge difference if the ABS light is on, I don't think I've seen a GM or VW over 6 or 7 years old without it on honestly. If there is a problem detected in the circut it just goes to conventional.

I'm not familiar with GM or VW, but, on a Suzuki, and I believe most SUVs, certainly all I have looked at - there is NO WAY the system can just "go to conventional" - it is "missing" some of the required parts.

The "non ABS" versions of Suzuki vehicles that had an ABS option, are fitted with an LSPV or Load Sensing Proportioning Valve that is not fitted to the ABS equipped models - the LSPV varies the fluid pressure applied to the rear brakes based on the load in the vehicle to reduce the possibility of the rear brakes locking, and the vehicle swapping ends in a panic stop.

The LSPV is omitted from the ABS equipped vehicles because the functionality is handled by the ABS system, and if the ABS system fails there is no way to provide that "brake balance" functionality.

It doesn't make a difference in this case because the vehicle was never equipped with ABS, and the original braking system is presumably still intact and functional.
Title: Re: 2002 build
Post by: beagle..t on May 28, 2016, 02:35:46 PM
So fordem are you saying that there is going to be a problem or is the ABS light just going to come on in the dash. I didn't swap brake booster or anything like that from the donor cause I didn't want ABS and it was more work that I didn't want to do. I just figured that I would just pull the light in dash
Title: Re: 2002 build
Post by: fordem on May 28, 2016, 04:52:29 PM
I don't anticipate there being an actual problem with the brakes, because as I said, the original braking system will still be there and in one piece.

If you've swapped the cluster & harness from the donor, the ABS light will probably come on - there's usually a relay that turns it on at "key on", and when the ABS controller completes it's self tests, it turns the light off - if the controller dies, is missing, or detects a failure, the light stays on - I would just take the bulb out.

Having said that - the electronics all "talk" to one another, so it's entirely possible for the ECU to get upset and throw a code if it doesn't hear from the ABS controller when it should - that's where the real challenge of the conversion lies.
Title: Re: 2002 build
Post by: beagle..t on May 28, 2016, 10:03:59 PM
that's good to know, I will keep the fingers crossed
Title: Re: 2002 build
Post by: nprecon on May 28, 2016, 11:19:21 PM
Great discussion points.
Title: Re: 2002 build
Post by: BRD HNTR on May 29, 2016, 08:20:29 AM
I do not get a self check not completed alarm, but a check of the computer will show that it has not been completed.  I am running on 93  LSPV.
Title: Re: 2002 build
Post by: beagle..t on May 29, 2016, 04:32:58 PM
so brd does your 93 have ABS? I'm just hoping that it throws the light on and doesn't throw a code. I guess time will tell. ***Question*** does the EVAP canister that is under the passenger side the same from xl-7 to my 2002 tracker. I just don't want to pull it if is the same. Well stopped raining enough today that I had the chance to swap gas tanks over, didn't want to push the xl in garage then do the same with the tracker. Didn't  get the skid plate back on cause it started to rain again and swapped over the wiring that's underneath that runs fuel ump and sending unit. Why swap the tank? well to my understanding with what I read is that the XL-7 has 2 gallons more than my 2002 tracker with the 2.0. So all that's left on the list to remove from the donor is door locks, exhaust and a couple odds-n-ends and anything else that anybody can thing of 
Title: Re: 2002 build
Post by: BRD HNTR on May 29, 2016, 06:53:05 PM
No my 93 does not have ABS.  I had the  Load Sensing Proportioning Valve, but that is not hooked up since I now have a 4-link suspension in back.
2005 ABS has its own computer, and to my benefit it is not on the Can Bus, so it is not telling the other computers it is not there.  So far I don't have a problem.
But you do have a problem, of sorts.  As you have a dash that expects ABS responses, it should illuminate wo  a response.  In 99 there were three lights for the ABS depending on what was happening.  In 2003 One light would warn of no signal from ABS.  If you car has to be inspected, it won't pass with out ABS functioning, just not safe.
As your Tracker has ABS, what is the difference between it and the XL7?  Your system may supply what is needed for the dash to be happy.
This is why having FSM's makes swapping much easier.
Title: Re: 2002 build
Post by: beagle..t on May 29, 2016, 08:23:38 PM
so I guess I will be keeping the gauge cluster from the tracker and see if I get anything when I get it all together
Title: Re: 2002 build
Post by: Perryd on May 30, 2016, 04:04:29 PM
I would keep it for sure, no point in tossing it. But I would try the xl7 cluster first. I think dealing with a abs light is going to cause you less issues than trying to get the tracker cluster working with all the xl7 wiring. As I said in my experiences abs lights don't usually interfere with the running and driving operation, besides triggering other lights for things like traction and stability control. You have bigger fish to try with this build I'm sure. keep it up!
Title: Re: 2002 build
Post by: Perryd on May 30, 2016, 04:07:19 PM
internet lagged out i repeated my post sorry *ignore*
Title: Re: 2002 build
Post by: Perryd on May 30, 2016, 04:12:15 PM
*ignore*
Title: Re: 2002 build
Post by: beagle..t on May 30, 2016, 09:05:40 PM
yes that's for sure I can deal with the ABS light ...but don't really want to deal with codes from no ABS from ECU. I will have to look at the FSM and see what it says for no ABS
Title: Re: 2002 build
Post by: beagle..t on June 17, 2016, 08:21:39 PM
Well nothing really new waiting for parts for timing chain and gaskets, might have found someone to do the work for me local which is nice. that's about all that's new just waiting on parts >:( I hate waiting ). xl-7 shell is gone  motor is washed and now clean, just waiting  :laugh:
Title: Re: 2002 build
Post by: BRD HNTR on June 17, 2016, 09:11:40 PM
Waiting is much harder to do than moving (in any direction) on any project.  I am with Perryd, hang onto the dash, but try the XL7 first.  Your system may supply enough signals to keep it happy, you are not talking about big differences in operating system.
Have you got all the wiring swapped out and landed in the body? 
Title: Re: 2002 build
Post by: beagle..t on June 18, 2016, 08:49:17 AM
ya wiring all re-routed 97% hooked up. interior could go back in like panels, carpet and seats but that's like half a day and once motor and tranny back in then I can figure out drive shaft and hook the rest of the wiring up. I shortened the exhaust so that it will be useable till duals come.
Title: Re: 2002 build
Post by: beagle..t on June 18, 2016, 02:17:38 PM
well just had a scare as I was removing some stuff that's in the way of timing chain removal   :o thought that the motor was a 2.5 instead of the 2.7 as I looked at the heads and it says H25 well off to the manual to find the serial # and its all good. I know that they use the same parts and same blocks just bored out more, but wow I thought that I wasn't getting what I want 
Title: Re: 2002 build
Post by: BRD HNTR on June 19, 2016, 06:30:16 AM
I know the feeling.  As my motor, tranny and TC came w/o a body attached, when I found the identification in FSM I immediately checked it thinking at that point I was stuck with what I got.  After confirmation that the motor was H27, it was a worth the work left to do.  If I had found H25 heads first it would been a very bad feeling.
Title: Re: 2002 build
Post by: beagle..t on June 20, 2016, 07:07:49 PM
parts to be hear by Friday, but most likely monday
Title: Re: 2002 build
Post by: beagle..t on July 08, 2016, 02:49:16 PM
Well all the parts finally showed up xmas in July, and talked to a guy that is interested in doing all the work so parts and motor will be heading over to his shop Tuesday afternoon.  I am trying to get this all finished by Sept  ( fingers crossed)   
Title: Re: 2002 build
Post by: Tan Zuk on July 08, 2016, 10:01:23 PM
Well all the parts finally showed up xmas in July, and talked to a guy that is interested in doing all the work so parts and motor will be heading over to his shop Tuesday afternoon.  I am trying to get this all finished by Sept  ( fingers crossed)

Hey, that sounds like cheating to me!

Seriously, I hope it all works out for you.
T
Title: Re: 2002 build
Post by: beagle..t on July 09, 2016, 10:42:21 PM
ya me too looking at the tracker and nothing really to do bugs the heck outta me (really bad) I just want the motor done so I can get back to work on it
Title: Re: 2002 build
Post by: beagle..t on July 12, 2016, 09:04:11 PM
well dropped motor off  to get work done should be ready in couple weeks as I told the guy I wasn't in a rush and he told me that it would be done before then. so it gets new valve, intake, oil pan, front and rear seal and o-ring that between the  block that has a tendency to leak. new timing chain and gears guides and tensioners. water pump and oil pump. So with all this work done I should be go to go for a while 
Title: Re: 2002 build
Post by: beagle..t on July 26, 2016, 06:19:24 PM
well motor will be done  tomorrow and will be picking it up Saturday and starting install Sunday :laugh:. So getting excited to start working on this as I only got 4 weeks till dead line .....in my eyes. I don't know if this pic worked but it is the front motor with all the chains and everything on, sure glad I got it done by others and not me
Title: Re: 2002 build
Post by: beagle..t on August 01, 2016, 07:22:34 PM
well picked up motor on Friday, put some stuff back on and took some off (exhaust manifolds) got tranny in and motor mounts bolted down. Now after along time not working on it trying to remember where stuff goes. tomorrow will be mating the motor and tranny together. Sure looks big in there compared to the 4cyl 
Title: Re: 2002 build
Post by: BRD HNTR on August 02, 2016, 11:04:16 AM
You still have a lot of room in there.  Good to see you moving forward again.  What does the driveline look like with the motor in?
Title: Re: 2002 build
Post by: beagle..t on August 02, 2016, 06:53:28 PM
no exhaust manifolds on. haven't looked at the driveshaft  fitment yet and now I got to get the wifes murano running again gotta change the alternator so tracker down again for a couple days, but on the high note motor is in  :laugh:
Title: Re: 2002 build
Post by: beagle..t on August 07, 2016, 08:38:51 PM
 So this weekend was a busy one, fixed wifes car so that I could work on tracker. I got the tranny mated and then realized I forgot the spacer  >:(so pulled all apart (2 steps forward 4 back) now back on track and back together flywheel/torque converter done, steering done hooked some wiring  hooked up. Still haven't tried driveshaft  Starting to come together better than I thought, hope that doesn't jinx me   
Title: Re: 2002 build
Post by: beagle..t on August 17, 2016, 08:19:29 PM
well a lot more progress done. exhaust manifolds and y pipe hooked up rear driveshaft fits ....so no lengthening or shortening thank god (didn't need to explain that expense to the wife). Front driveshaft  done, interior half way there  seats and console left, rad and AC stuff grill hood and a couple little odds and ends that take way longer to do than expected. Maybe by the weekend or next but when it all comes down to my deadline I think that I might make the test run by Sept1 or earlier yah me
Title: Re: 2002 build
Post by: beagle..t on August 28, 2016, 08:28:53 PM
Well alot has happened in the last couple weeks everything hooked up had a battery arc problem fixed that, now went to start and code PO340 camshaft position sensor A bank 1 malfunction so no VROOM VROOM till that's fixed
Title: Re: 2002 build
Post by: Drone637 on August 29, 2016, 01:36:04 PM
If it makes you feel better we burned out a computer last time we tried to fire up my Red Tracker.  :D
Title: Re: 2002 build
Post by: beagle..t on August 29, 2016, 07:24:23 PM
Is that the cobalt conversion at BRD HNTR... How's that going?
Title: Re: 2002 build
Post by: BRD HNTR on August 29, 2016, 09:22:09 PM
I think that the ECM fried in the accident that cut one third of the power wires to the ECM.  We never had appropriate responses to power up.
We have a reflashed computer now, still need to get clutch master cylinder that will connect to the chevy quick disconnect fitting.
Title: Re: 2002 build
Post by: beagle..t on September 06, 2016, 09:37:29 PM
well found out the camshaft sensor was out 1/4", I guess threw all the movement the motor has taken something had to move. So fixed that and found that the spark was to much, huh go figure to much spark...uhmm . so new plugs installed and found injector plug was not totally plugged together. so scanned again for codes and nothing showed and said to son turn it over to see if it will fire ,and it coughed so tried again and VROOM she's alive again. Now just need to do a bit of tweaking and I'm all done ....for now I will take video of running tomorrow and post ,just got to dark tonight
Title: Re: 2002 build
Post by: Ridjobradi on September 07, 2016, 11:44:58 AM
Congratulations on getting it running.  We look forward to seeing more of it.  I guess that means I need to get back to working on mine.  I am jealous of all the engine swaps, but mine is still running well.
Title: Re: 2002 build
Post by: beagle..t on September 07, 2016, 05:42:39 PM
the previous 2L motor ran great it only had 180,000 kms on it. My problem was brd hntr threw a bug in my ear. I really appreciate all the advice I get from all the members here when I ran into problems
Title: Re: 2002 build
Post by: Ridjobradi on September 07, 2016, 09:23:26 PM
Any chance that you are parting the 2.0?

Sent from my SM-G900V using Tapatalk

Title: Re: 2002 build
Post by: BRD HNTR on September 08, 2016, 01:44:27 AM
It is good to hear that it is actually running again.  Not that I didn't think it wouldn't, but plugs that aren't quiet connected, sensors that got moved, can be real bugger to find.  Hope to see you this fall with a big smile across your face.  It will pop up most every time the skinny pedal gets pushed a little harder than usual.

I was going up Hwy 12 close to the summit on the east side following a Dodge PU (that had been running at least 5 under the speed limit) and a passing lane came up which he pulled into the slow lane and sped up.  I don't think he ever had a Tracker on 33's drop two gears swing around him and leave him wondering if his diesel had quit.  My wife looked over and said "Did he think that was speeding up?"  "When this running right it sure loves to sing.  He didn't stand a chance."  I was smiling that big smile (because I don't usually get that reaction when passing cars that don't want to be passed), 2 big smiles at one time takes practice to control.
Title: Re: 2002 build
Post by: Drone637 on September 08, 2016, 10:23:41 AM
To be fair, yours makes a pretty good racket when you decide to drop two gears.  :D
Title: Re: 2002 build
Post by: beagle..t on September 08, 2016, 08:09:07 PM
Ridjobradi all 2L stuff gone threw most of the stuff away all that's let is rad, alternator, starter, and gauge cluster. So tweaked throttle and kick down cable, hood is back on. and took it  for a rip and didn't use power mode nor did I take off OD and it moves good. Bumper needs to be installed, then I can hook winch and lights up and finish interior which is only radio and CB. Then its all done. the only lights that are on the dash are the ABS, Airbag, and emergency brake but that could be from there is no ABS....So BRD HNTR when I come down next to see you what is the next mod ....lol I will bring the tracker down next time down when your home (happy hunting)
Title: Re: 2002 build
Post by: BRD HNTR on September 12, 2016, 11:23:28 PM
.So BRD HNTR when I come down next to see you what is the next mod ....lol I will bring the tracker down next time down when your home (happy hunting)
I am looking forward to that.  I am back home for the week, hoping to get back up this weekend through most  of next week.  When are you going out?
When you stop by, I will get my camera out and show others what you can do (so make sure its clean). :laugh:
Title: Re: 2002 build
Post by: beagle..t on September 13, 2016, 09:30:58 PM
the next couple of weeks are pretty busy, I will let you know when I'm coming down and will give you lots notice so that you are home
Title: Re: 2002 build
Post by: beagle..t on September 13, 2016, 10:04:17 PM
oh yeh almost forgot .. winch bumper on and winch bolted back on bumper . If they steal my winch off my bumper it will be worth there pain. I forgot how tight it was to bolt it on. Well big test run this weekend hope everything works good
Title: Re: 2002 build
Post by: beagle..t on September 18, 2016, 12:59:27 PM
well drove tracker for test run 500 kms, 1 tank of gas of mountain hwy driving. Drove great no breakdowns cruzes nicely at 70 mph. Now I have exhaust leak at y-pipe not a big deal as dual exhaust will fix that, and I will tighten the bolts up again 
Title: Re: 2002 build
Post by: nprecon on September 18, 2016, 05:02:47 PM
That is great to hear, Beagle.  How much difference do you feel in the power?   Is the smile hard to get off your face?
Title: Re: 2002 build
Post by: beagle..t on September 19, 2016, 04:48:20 PM
well the power is definitely there, up to 60 mph in no time faster than the 5 spd would get there . I cruzed up long steep hill at 70mph with no problems at all. I kept at 70 so that I could hear any rattles or noises that I didn't like. happy on how it ran
Title: Re: 2002 build
Post by: beagle..t on September 25, 2016, 07:20:20 PM
well found out that I lost both bolts for the exhaust from the Y pipe , so that accounts for the exhaust leak so now new bolts to be put in before she goes on the road. Also with the motor weight and winch and bumper it sits bum high again so thinking that I will get bigger coil spacers and start swearing trying to get them in, but that will be down the road (I will have to deal with the front end sag)
Title: Re: 2002 build
Post by: Drone637 on September 26, 2016, 05:51:24 PM
What are you using for your front spring currently?  Might be easier to get a heavier OME spring then bother with spacers.
Title: Re: 2002 build
Post by: BRD HNTR on September 27, 2016, 04:38:47 AM
What are you using for your front spring currently?  Might be easier to get a heavier OME spring then bother with spacers.
Did we have the lifted XL7 springs (with one coil cut off) on the race car?  If so that would be about what he needs, as his bumper and winch is close to mine.
Title: Re: 2002 build
Post by: beagle..t on September 27, 2016, 09:08:16 PM
I have GV fronts springs it had the 2.5, and they were 1/2"-3/4" taller than stock 4cylinder ones.i think that I need anywhere from 3/4"-1" more to level it out again
Title: Re: 2002 build
Post by: Drone637 on September 28, 2016, 05:08:09 PM
Might go with the GV OME or the XL7 OME springs, depending.  As long as you don't lift it to much and start blowing cv's.
Title: Re: 2002 build
Post by: beagle..t on September 29, 2016, 07:12:02 PM
I was thinking of putting bigger coil spacers, like 2" instead of 1 1/2" in the front, unless I can find xl-7 springs for cheap ,as I had a set but everything is on hold so wont happen this year as wifes side of family screwed me over, and want to kill all. but that's another story. if you look at a xl-7 they sit bum high too
Title: Re: 2002 build
Post by: Drone637 on September 30, 2016, 03:17:57 PM
Here is a good chart to compare the different OME spring options and how they compare to stock:

http://www.lowrangeoffroad.com/images/charts/front_springs_chart.jpg (http://www.lowrangeoffroad.com/images/charts/front_springs_chart.jpg)
Title: Re: 2002 build
Post by: Ridjobradi on October 01, 2016, 07:47:11 AM
I have OME 962 springs in the front of my Sidekick.  I would prefer to change to OME 956 springs.  I don't have a V6 or a  bumper and winch to weigh my front end down.  If you are interested in the OME 962 springs, I can pull them out and order new ones for mine.
Title: Re: 2002 build
Post by: beagle..t on October 01, 2016, 09:12:19 AM
those are the same size I got in now, but thx for the offer
Title: Re: 2002 build
Post by: Ridjobradi on October 01, 2016, 09:55:30 AM
Are the same spring rate or just the same length?
Title: Re: 2002 build
Post by: beagle..t on October 01, 2016, 06:12:18 PM
length is the same they came from a 99 Grand Vitara with a 2.5 manual they are a beefer spring that was stock
Title: Re: 2002 build
Post by: BRD HNTR on October 04, 2016, 10:25:34 AM
I am running 956 (13" 500# rate) and a 1" spring cup modification.  Instead of a spacer you might want to think about modifying the spring cup to keep A-arm spring seat closer to same angle of top spring seat and prevent it from bowing.
(http://lh3.ggpht.com/CrawlersNW/SO1yarlbtzI/AAAAAAAACUo/koqdvxEtt5E/s512/CIMG3069.JPG)
Title: Re: 2002 build
Post by: beagle..t on October 04, 2016, 02:50:33 PM
brd htnr I'm not coming down too see you if you are going to try and convince me that I need to do this.... lol . I would like to do the widing mod but lost welder and shop as moving in Nov1 ,but will have 2 car garage to play in
Title: Re: 2002 build
Post by: BRD HNTR on October 05, 2016, 06:44:50 AM
brd htnr I'm not coming down too see you if you are going to try and convince me that I need to do this.... lol . I would like to do the widing mod but lost welder and shop as moving in Nov1 ,but will have 2 car garage to play in
When stuffing a wheel on inside turn, the spring would compress the brake caliper, and then not have brakes for two strokes.  Took a while to figure out what was happening.  You have 16" wheels, so that may change things,.  If you do run into occasionally no brakes on the trail, just stop stuffing the front end during turns. >:D
Looking forward to meeting up again. (So maybe only a few small suggestions, will be coming forth.)
Title: Re: 2002 build
Post by: beagle..t on October 06, 2016, 12:05:26 PM
no 16" wheels, I still have 15" with the 30x9.5 and running bfg AT. Taking another trail run this weekend ...500+ kms and going to try the 4x4 out as I'm going hunting in a new place. When I get back from the final test run this should tell me if I can trust it to get me where I need to go. should be able to get down there mid November to mid December but I will PM you when I'm coming down
Title: Re: 2002 build
Post by: Waterman on December 10, 2016, 07:28:54 AM
Great job
Title: Re: 2002 build
Post by: Perryd on January 15, 2017, 07:11:32 AM
I only just got around to reading this now, love the build. Make me think of what my 03 could have been like if it wasn't rusted to death lol. But I must ask, where's all the pics/vids???
Title: Re: 2002 build
Post by: beagle..t on January 15, 2017, 10:06:12 AM
there was a bunch but after the site crash I lost the pictures that I posted, and got new comp where they were stored on. As of now she just sits in the driveway and drive it once and awhile, trying to save money for a couple more add-ons like the 3" extreme lift from 4xfourart, rear locker, transfer case gears, and 33"-32" tires
Title: Re: 2002 build
Post by: beagle..t on March 16, 2017, 04:54:38 PM
well picked up some new shoes 33x12.5x15 cheap and tried the fitment test ......well they fit but the mule will be losing some metal around the fender area need 1"1/2 on the rear and 2" in the front hope I got enough room for it
Title: Re: 2002 build
Post by: beagle..t on March 16, 2017, 04:56:58 PM
front tire pics and they stuck out abit
Title: Re: 2002 build
Post by: Drone637 on March 16, 2017, 05:05:59 PM
Time to start cutting!

How is your clearance on turning on the front end?  I had to hammer in behind the headlights on my 92 when I put the 33's on.
Title: Re: 2002 build
Post by: beagle..t on March 16, 2017, 06:50:43 PM
the front of the front tires there is a ton of room.... I think I might have to cut front fenders 2" back
Title: Re: 2002 build
Post by: beagle..t on March 16, 2017, 06:51:43 PM
here is the front
Title: Re: 2002 build
Post by: BRD HNTR on March 18, 2017, 05:33:22 PM
This is going to be interesting.  I didn't have to do any trimming on the back wheel wells, and the front was easily done(?).  Mike Hagen had to trim his back and writes about in it http://www2.zukiworld.com/feature_project-zr3-the-way-a-tracker-should-have-been-built/ (http://www2.zukiworld.com/feature_project-zr3-the-way-a-tracker-should-have-been-built/).  Also Ben Peterson here on ZW is running 35" tires on his Gen1. 
Both Jegs and Summit have complete inner wheel wells from $90 US and up if you need to go that far.  Front fenders are much easier as there isn't a metal inner fender to work with.  After cutting the opening, bolt the fender back on body before attempting to bend the lip back under.   This will position the fender so that it won't readily warp as you bend that inner lip, and use three or four passes when bending the inner lip (don't try doing the 90 degree bend in one pass). 
With 33's all that extra power is going to take a bite, so will mileage (just a little).
Title: Re: 2002 build
Post by: beagle..t on March 18, 2017, 08:37:33 PM
this is my question to you BRD HNTR you are running 33 and by the way your rig is looking how much power loss and rubbing to you have on top of wheel wells and full stuff .....thinking that maybe will trade for 31's
Title: Re: 2002 build
Post by: BRD HNTR on March 19, 2017, 09:14:29 PM
I rub on hard flexing on the rear wheels.  I think that Gen 1 must have higher wheel wells, and I have taller springs I am at 14.5 inches to bottom of frame with no BL.  When I went from 30" tires with speedometer about 10% off to 33" tires my speed is right on, I am running an electronic speedometer from late model(?) GV.  My rpm's are at factory 2600 at 60 mph.  I don't know where your speedo is what your 60 mph rpm's are. but if your gear tire ratio's are going slower than speedo says then larger tires won't hurt as much as if your speedo is slow already.   (I think they set the tire gearing ratio's for optimum efficiency.)
I have a larger hp gain to play with, you already had a hot rod.  I did notice a big difference in performance and mpg when I went from Pro Comp "Extreme's" to Toyo Heavy Duty Mud Tires.  Same size tire but much heavier.
Title: Re: 2002 build
Post by: beagle..t on March 20, 2017, 07:10:38 PM
BRD HNTR I hear what you are saying  and looking at how much I have to cut out and still not knowing if I can turn after all the work,  I'm think that I'm going to trade for some 31 MT and leave it at that. I'm worried that if I put the 33's on that I might lose to much HP but they were too good of a deal and I might have someone interested in trading straight across. I don't want to lose the power I have now just to gain a 1"1/2 clearance then mpg will go down HP goes down so ya will stick with 31's
Title: Re: 2002 build
Post by: beagle..t on March 27, 2017, 08:20:24 PM
well traded the 33's, it  was just too much cutting to do and don't have the money right now for the extended A-arms or lift I want, so traded for 31x10.5x 15 goodyear wrangler territory with 75% tread and ordered a new mod  ;D.....waiting for my new rear locker to show up. would have loved an ARB air locker but $$$$ doesn't grow on trees as I wish it did :laugh: . Just trying to get the truck sound for sept ran into a couple snags as I was changing brake rotors
Title: Re: 2002 build
Post by: beagle..t on February 07, 2019, 07:31:21 PM
well its been just about 2yrs since the swap and I still have it and it still runs great doesn't get use a lot weekend wheeling and sept to dec and that's about it so hear are some pictures