Im getting some pinging noises from the front end ONLY while im totally stuck in 4x4.  Otherwise seems fine.  It does not inspire confidence to stomp on the gas and this is only in 4 High (i now know better than to stomp on it while in 4lo).Any ideas what I'm hearing?  Axles? Diff?  Is this a sign im gonna blow something again?  Anyone else get these noises?

Can you describe this 'pinging' noise you are hearing a little better?  Is it an actual 'pinging' noise or does it sound more like a 'ratcheting' noise?  If it is more a ratcheting (light-quick clicking) noise, I would be thinking a front hub wasn't fully engaged but this could only occur if you have manual hubs on your truck.

it could just be your CV's? 

Check your back diff mount.  I seem to recall that noise, and it can eat a hole in your bellhousing in a short while (if that is what it is).

Ok thanks for the replies guys, especially Samurai Dan since I took about a month to answer his last pm lol.

It's a pinging not a click/ratchet sound, and definately coming from the front.  I'm thinking (and hoping) it's an axle getting worn.  BRD HNTR: are you thinking of a sidekick 3 link?  because the vitara is 4 link rear so im not sure what the diff mount would be as theres no centre link.

I guess im thrown off by the fact that it's not happening while rolling regardless of what angle the cv's are at..only when im hung up/buried in that slushy snowy muddy rocky stuff...you know...the good stuff .  But man do I hate that feeling like something could break if I push it a lil too far.

Oh and I do have manual hubs.

I think by rear diff mount he means the mount on the crossmember for the rear of the front diff.

I think by rear diff mount he means the mount on the crossmember for the rear of the front diff.

ok that makes sense lol

Yes that is what I meant.  It made sense when I thought it.

Well I finally got around to investigating the front end...I think the problem is that the housing is cracked...again
Heres the picture of the carnage although I dont know why anyone would want to subject themselves to such horrors.
http://i1155.photobucket.com/albums/p546/EvilMetalGod/IMG00062-20120331-1518.jpg

I don't think I can justify putting another aluminum diff housing in there...this is the 3rd time wrecking the diff in 3 years!

That sucks bush buster!

When my first diff housing broke, it cracked at the mount. i was stuck and doing the old forward reverse technique but the torque applied in reverse just snapped the mount in half. i wasn't really a fun experience, so i know what your going through.

do you think you cracked the housing from actual physical contact or just the stresses applied when wheeling?

before stupidly selling your friend my tracker i was finding xl7 steel fronts in the $400 range, i never broke that aluminum case/housing (which i always thought i would whenever i had to get on it..) but did break a bracket once...  if you can't find anything out there let me know, i can check around here, there are lots of zuk ppl in this area.

Im pretty positive it is cracked from the stress of wheeling.  Someone from this the ZW forums is sending me a steel diff housing and steel third housing for $260 shipped. Right now I'm trying to locate a rebuild kit and then i plan to have a mechanic install the gears from mine into the new housings.

Update: Lowrange has informed me that the diff rebuild kit is the same for the samurais, sidekicks and vitaras.  120 for the kit...suzuki wanted 60 bucks just for one of the four bearings , not to mention the seals!

Also im thinking of putting a locker in the front while im at it.  Since i have manual hubs i could unlock it for the street, and that has me thinking i could even do a full locker since it does not need to be street friendly...would it be possible to just weld the gears?  I also wonder if there would be any negative effects of being in 4x4 locked in the front but open in the rear? Anyne care to share their opinons on locking the front of my vitara?

I believe a solid lock front makes steering hard/impossible under some situations off-road.  You might have to get out and unlock your hubs to make some tight bends, and then you'd only have 2WD to get round them.