I have a GV V6 steel axle going in the front of my Track/Kick. I'm using 26 spline drive shafts so I can apparently retain all the GV diff assembly with the 5:83s. This gives me the option of using the GV 4x4 select mechanism which I understand is vacuum operated. Can one of you GV gurus out there tell me what else I would need to hook it up?
Cheers
James

It's actually pressure actuatated. There is a very small pump located above the front bumper. This pumps pressure to lock the front housing.
I had to replace the rubber 3" hose last night. The 4wd indicator would just blink and blink. This represents a problem with something.  I knew it wasn't mechanical. Found the culprit to the hose. Replaced it with 3/16" fuel line and problem solved.
Needs pics I'll take some tonight? Let me know.

OK so I need a small pump I can sort something out there. There must be an electrical switch on the tcase as well I guess. is the pump pumping all the time it is in 4wd? Pics are always good
Thanks
James

I'll get some pics up later tomorrow. Got back on-line at home after dark. Sorry.

Ebay usually has a few listed. This dealer is parting out one that may still have it, "ttruckcenter".
Here it is, $1 no bids, closed, http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33626&item=7906254840&rd=1&ssPageName=WDVW, searched under 'vitara pump'.
It's actually a pressure pump, and not a vacuum pump, that's how I found out the pin hole with bubbles.

As for a switch, I'm thinking yes on the shifter, which shows 4wd, then the pump is activated by a relay.

Pump has a circuit breaker as after I pulled the broken hose off, it kept pumping. Then totally stopped. Couldn't find the fuse box (suppose to be in engine bay), but there are several breakers on right fender. Turned off the key, replaced the hose, and hoped pump would come back on. 4WD indicator showed and I heard a faint brrr. Tested the pump by pulling the hose and it was working......Yah.

Aren't you in England?

You could contact ttruckcenter on ebay about pricing and shipping. But really why bother with all this trouble when a late model 26 spline carrier will happily work?

Have you seen the write-up on Zukipilot's front axle swap here on Zukiworld?

I forgot about the 4wd light  . I could certainly wire a relay into that and a pump should be easy to get. I am in the UK, the Jimny has the same sort of arrangement so there should be loads in the breakers. I broke my original axle on the Sweden Off Road tour and ended up fitting a 22 spline front. The GV is 26 spline and I still have my original driveshafts and spares. Also I broke one of the manual hubs a couple of months ago so I figured I could just use the GV arrangement. The GV axle is being fitted for its strength. I looked at Zukipilots write up a while back, I shall have another look.
Cheers

I have the pump now, there are two pipes, I guess one is an intake and one goes to the axle. There are three wires, red, black and pink. Any idea how these are wired up? The guy at the breakers cut the wires off the loom so I have the plug  

I have the pump now, there are two pipes, I guess one is an intake and one goes to the axle. There are three wires, red, black and pink. Any idea how these are wired up? The guy at the breakers cut the wires off the loom so I have the plug  

I have the 2003 Service Manuals and I'm looking at the wiring diagram on pg. 9A-20. Black is ground. Pink is to a transistor, NPN???. Red appears to be power from the ECM/PCM.
Somewhere there is a Orange/white for the 4wd lo switch. It's also connected into the ECM/PCM. This is the same for the auto trans and cruise or without cruise.
The ECM/PCM feeds to the 4wd indicator through a orange/black wire.

That's all I got off the pages. Hope this helps. If you need, I'll scan them at work tomorrow. Let me know.

I think I can guess it most of it from there. I'm a little surprised it goes into the ECM but I suppose the transistor is switched at 5V, I guess it also stops it being activated while the engine is off and its in 4wd. The guy at the breakers reckons the pump pulls it in and then it holds in by itself? so maybe its on a timer too. Does the section on the ECM give any details?
Cheers
James

I think I can guess it most of it from there. I'm a little surprised it goes into the ECM but I suppose the transistor is switched at 5V, I guess it also stops it being activated while the engine is off and its in 4wd. The guy at the breakers reckons the pump pulls it in and then it holds in by itself? so maybe its on a timer too. Does the section on the ECM give any details?
Cheers
James

I can assume that you friend is correct about the transistor and for when the engine is off. Can't see why the pump would stay on to keep it engaged when engine isn't running. Don't know anything about a timer.
I didn't see any separate section for the ECM itself.

OK thanks. Do you know anywhere I can download the FSM?

OK thanks. Do you know anywhere I can download the FSM?

No I don't. My home scanner is not working. I'll pull the book into work tomorrow and get a couple pages copied there. I'll have to post into my webshots page for your review. Hope this helps.

Scanned the diagram and placed it in the my webshots under Suzuki Other Stuff. Hope this helps.

screwed up placed my reply in kick wiring harness info

regards  rob

my 2 cents worth

there is an orange-black wire between the t-case and the computer that signals the computer to activate the pump for the front diff. if you mess with the 3 wires that go to the pump from the computer  all sort of strange things happen. there is also an orange-white wire from the t-case to the computer that signals the computer and auto trans for lo-range.

regards, rob

OK I've cut and pasted your reply into this thread so I don't add to the other one. Thanks for that I will have a look at my tcase, there look to be a couple of 'spare' wires on it. The orange/white must be fron the 4wd indicator switch. I wonder if the VSS is monitored as well as the handbook says you can't (shouldn't?) shift between 4wd and 2wd over 60mph. I was away at a 4wd show this w/e so I didn't get a chance to try anything, maybe next w/e. It is up and running again though and the trip to the show was a lot easier going with the 5:83s fitted

Edit: It was pretty pathetic on the ramp though, scored 534 with the rear wheel spinning on the grass. Shame as I've never had the chance to ramp it before, maybe I'll get another go next year with 4wd engaged.