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?


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

Your approach is most logical,
I have planned on doing this same
mod.  The later Track/Kick/Vit flange
is 26 spline, just like the output on
the T-case, it also is the larger bolt
pattern that fits the flanges on the
driveshafts of the later models too

I think an 8mm bolt should hold fine,
this bolt only holds the SYE onto the
output, it really takes no load, so it
need not be very big

To use the differential flange you would
need a stopper in the center, where now
it hase none because this is where the
splined pinion shaft comes thru

Let us know how it goes  

Good Luck
Wild

Your gunna make me go out in my junk pile and get 90 wt oil on me arn't ya.  

Your approach is most logical,
I have planned on doing this same
mod.  The later Track/Kick/Vit flange
is 26 spline, just like the output on
the T-case, it also is the larger bolt
pattern that fits the flanges on the
driveshafts of the later models too

I think an 8mm bolt should hold fine,
this bolt only holds the SYE onto the
output, it really takes no load, so it
need not be very big

To use the differential flange you would
need a stopper in the center, where now
it hase none because this is where the
splined pinion shaft comes thru

Let us know how it goes  

Good Luck
Wild

i dont get what you're saying here wildgoody, do you mean the later sami/sierra tcase flange will fit the vit/kick/track 26 spline?

what about the bolts fouling on the housing? i cant see a way around this

Hi Antt, hows it going?

looking back 22 pages, i found this for you.

not too sure if it helps, but have a read anyway.

cheers
Steve

http://www.zukiworld.com/cgi/yabb/YaBB.pl?board=suzuki_talk;action=display;num=1108788087

thanks sikid

its a little more complicated than that , the track kick 3rd flange does match the splines on the tcase shaft ,but their is not enough yolk on the flange to reach the bearing race in the case and the flange also runs into the ceal of the case , what im doing is parting off the yoke on the driveshaft at 3'' then boaring the flange so that is a slip fit over the yoke then welding the flange to the yoke ,boaring the yoke out on the flange side 1.175"x.675",then making a slug 1.175"- x.5" and welding the slug in the center of the yoke ,this keeps the flange off the ceal and reaches the bearings. drilling a hole in the center of the slug , im going with a 1/2 20 bolt , if anyone has done this differentley or easyer let me know ,this is what i came up with

this is the most informative post there. from what i can make out mesjr2004, you are going to cut the slipyoke off like i've done in that 3rd pic up the top. then use a lathe to make the hole in the flange bigger so it can slide over the end of the slipyoke, weld these two together, then putting a plug up the inside of the slipyoke, then drilling this and bolting it on so it keeps the slipyoke off the seal on the tcase. is this about right???

heres a pic i've done of what i think you're saying  

Don't forget to drill out a little hole in each to bolt the new assembly to the output shaft.

~Nate

Don't forget to drill out a little hole in each to bolt the new assembly to the output shaft.

~Nate

thats the easy bit