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need help with sidekick 5.13 gear swap into sammy

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need help with sidekick 5.13 gear swap into sammy
« on: January 09, 2011, 01:30:07 PM »
so a few months back me and my dad purchased a sammy and it had 5.13s up front and 3.73s in the rear and the front drive shaft had been takin out...we had been told that the third member from a sidekick would bolt up to a sammy but we got the rear third member from the sidekick and after we got our third member out we quickly noticed it wouldnt fit so i did some research and found out that the sidekick gears need to be swapped over too a sammy 3rd member. so does anyone kno what i can do and if the rear side kick gears can even fit in the sammy 3rd member
so please help me i really just wanna get out their and start wheelin already but it seems like its a light at the end of a tunnel for me right now 

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Offline Hustler

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Re: need help with sidekick 5.13 gear swap into sammy
« Reply #1 on: January 09, 2011, 04:33:43 PM »
wont fit bud, u need the front gears from a kick.

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Offline ack

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Re: need help with sidekick 5.13 gear swap into sammy
« Reply #2 on: January 09, 2011, 07:26:38 PM »
so a few months back me and my dad purchased a sammy and it had 5.13s up front and 3.73s in the rear and the front drive shaft had been takin out...we had been told that the third member from a sidekick would bolt up to a sammy but we got the rear third member from the sidekick and after we got our third member out we quickly noticed it wouldnt fit so i did some research and found out that the sidekick gears need to be swapped over too a sammy 3rd member. so does anyone kno what i can do and if the rear side kick gears can even fit in the sammy 3rd member
so please help me i really just wanna get out their and start wheelin already but it seems like its a light at the end of a tunnel for me right now  


The reason why the aluminum Sidekick unit will not install is because the sidegear spline count is not the same as the Samurai's axle shafts' spline count. It is possible to to swap the side gears, but you have to tear down the differential and you end up with a rear dif in a puny aluminum housing.  Not good.

The Sidekick rear differential simply will not fit into the Samurai axle - it is too large.

The absolute BEST solution is to harvest the FRONT 5.12 ring and pinion from the sidekick and use them in the steel Samurai housing.  Since you'll have to tear the differential completely down, you might as well install a rebuild kit (Yukon sells them through many Sauzuki vendors).  

You will need a way to hold the spider gear pins in place. I suggest "cans" that are built specifically fo this purpose.  See http://www.acksfaq.com/difcans.htm for a description.  Cans are sold by many Suzuki vendors.

There is one problem with this:  Rebuilding a differential does require patience, somewhat specialized tools and time if you have never done something like that before.  You might want to enlist the help of someone experienced with the process (beer and pizza is suitable currency!).  Or just take it to a reputable mechanic...

I hope that this helps!
« Last Edit: January 09, 2011, 07:30:21 PM by ack »
Ack

'88 Samurai, '88.5 Samurai TT, '11 Ford Transit Connect XLT
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Offline wildgoody

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Re: need help with sidekick 5.13 gear swap into sammy
« Reply #3 on: January 09, 2011, 07:38:26 PM »
The problem isn't really the aluminum 3rd member, it will hold up fine
in a Samurai, it takes no stress that makes them fail in the Sidekicks.

What you don't want is the 2 spider gear front Track/Kick carrier, so you
need to take the carrier from the Sammy rear and put the 5.13 gear on it,
stick it into the front Track/Kick housing, set the backlash, which is the only
adjustment needed because you didn't remove the pinion and disturb the
setting and put that into the Sammy, you will need a can still to retain the
pins, but other than that, you can do this swap on the bench with dial indicator

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Re: need help with sidekick 5.13 gear swap into sammy
« Reply #4 on: January 10, 2011, 10:04:58 AM »
so just to be clear yall i can use my rear sidekick 5.13 gears to do the swap?? cause all i have been hearing about is the front gears. also i do have the axle that the gears came out of would it be easier to a sidekick axle swap then messing with all those gears

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Offline Drone637

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Re: need help with sidekick 5.13 gear swap into sammy
« Reply #5 on: January 10, 2011, 10:23:22 PM »
In order to use the rear gears you have to make what is called a hybrid housing.  That is where you take the axle tubes from a Samurai housing and put them on the tracker center section.  While it can be done by hand you will need a full shop to do it, or to buy a Hybrid Rear from a third party company such as Trail Tough or Hawk Suzuki.

The reason everyone mentions using front gears is the front ring and pinion is the same physical size as the rear ring and pinion on a Samurai.  You can take both a front third member from a tracker, a diff can and the rear third member from your Samurai to a qualified shop and they should be able to put things together for you.

Or just give one of the shops such as Trail Tough a call, ship them all the parts and they will ship you back the finished product.
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