Hi, I have a few questions regarding my unmodified 1999 Grand Vitara, 2.5L V6, 5-speed, 4x4.

What's this I hear about the front differential fill plug is too low?  That I have to jack the front end up in order to get at least 1.2L in?  Something like that should be a sticky!

When I am in 2WD mode, I can see my front driveshaft is not turning (which is correct) but my front CV shafts are turning with the wheels.  Does this mean the front ring gear and differential is turning all the time as I drive, or is the front differential disconnected from the CV shafts?

Well that's all I can think of now, I know I had more questions but I'll come back when i think of them

Thanks
James

you have a vauum disconnect in the diff for the front end. the CV's will turn all the time unless you put hubs on that can be unlocked.

So you're saying the front differential IS disconnected from the CV's while I'm in 2WD?  In other words if I'm in 2WD and could magically see inside the front diff as I'm driving down the road, the big ring/crown gear, pinion, side and spider gears will just be sitting there content, not moving?

So you're saying the front differential IS disconnected from the CV's while I'm in 2WD?  In other words if I'm in 2WD and could magically see inside the front diff as I'm driving down the road, the big ring/crown gear, pinion, side and spider gears will just be sitting there content, not moving?

Thats correct. When you shift the transfer case there is a air pump under the front bumper that creates positive pressure to engage the front diff.
Right now you have drive flanges on the end of your front axle/cv's. To totally disconnect all the rotating mass you would have to upgrade to manual locking hubs.

Ok that's good.

Now what about the gear oil level in the front diff, that the fill plug level is too low on early grand Vitaras?

Oh and another question, is there a timing belt that needs to be replaced?  My 1999 GV is getting close to 100,000kms; or is there any major engine services due up.  Replace a chain or something, I mean.

I have read (on this board, I think) the thing about the front diff - try a search.

The timing chain is not a lifed item - it's intended to last the life of the vehicle.  If you use 5W30 engine oil it may well do so.

So, no major "lifed items" to really worry about other than the standard driveline servicing, brakes, serp belts yada yada.  Good to know.  Fully intend to use 5w30 religiously.  Still mulling over switching to synthetic as far as engine oil goes, but for the transmission and t-case I am really considering synthetic 75w90 which I hope will help with the -25C morning shifting feeling like a spoon in a jar of cold peanut butter.  YannowhatImean.

Ok here's another question.  I'm also thinking about a remote-starter.  Now putting a remote starter on an automatic vehicle is easy, but on a manual it has to be done in such a way that it bypasses the clutch safety switch and won't start in gear.  So what I was thinking is, it would be great if I could set it up so the remote starter will only work if the T-CASE is in neutral.  That way it wouldn't matter where I leave the shifter if I forget, if there is some sort of electrical way to signal the t-case is in neutral only (not 2wd too).  It would be great because I could park, set parking brake, put t-case in neutral and put trans in 2nd, that way when I jump in to go the trans and t-case will both be warmed up.  Is there a signal of that type?

James

...if there is some sort of electrical way to signal the t-case is in neutral only (not 2wd too).  It would be great because I could park, set parking brake, put t-case in neutral and put trans in 2nd, that way when I jump in to go the trans and t-case will both be warmed up.  Is there a signal of that type?

As far as I can see, there is not.

In Sidekicks & Trackers the T Case switch provides a ground unless the shifter is in 2WD.  In the GV, the switch provides a ground in 4H and 4L, but not N or 2H.  So you could rig up a circuit with a relay to bypass the clutch switch with the TC in N, but it would also bypass in 2H.  That's ok if you always, always leave the truck with TC in N.  Frankly, I would not do that unless the ground was dead level, because the handbrake could fail.