Well today I ripped apart the front end of my tracker and "fixed" my broken carrier housing.


I, like many others, fell victim to the weak "ear" that bolts the housing to the pinion mount on the front cross member.

Due to the vast amount of torque caused by my heavy foot,:P The ear got sheared off one day when I was doing a steep hill climb.

The loss of the pinion mount caused the whole axel housing to rotate upwards which then caused my front U-joint to come in contact with my bell housing.  

Luckily enough after the first big THUMP I heard from the U-Joint kissing the bell housing, I immediately took my truck out of 4WD and limped out of the bush in 2WD.

Anyhow…

Today I fabricated a LARGER, SOLID ear (Hence operation Dumbo ) that wraps around one side of the housing.  The job was kind of a pain in the |removethispart|@$$. I had to disassemble the R&P assembly because I was afraid that the heat thrown off by the welder would melt the pinion seal.  (Good thing to because that thing was scorching by the time I was finished.)


I will post pics of the new mount tomorrow.  I forgot to bring my camera today, and my truck is still at the shop because I haven’t re assembled the carrier yet.  

Stay tuned!

Sounds like somthing I should fab up while I'm cutting out pieces for the lift.   I was thinking of just making a bolt on support colar to limit upward (reverse) movement.

Just a thought?  Why don't I hear of guys running Sammy steel carriers in kicks?   Sammy rear is alread 26 spline, front carrier & 3'rd is same as a kick...   You would have to fab the ear but this is a week link anyway...   I know that you'd still have the thin aluminium housing issue, but this is being delat with by the hybrids, Anvil, and xl-7...

KREG YOUR TALENTS JUST SEEM TO KEEP UNFOLDING ONE TASK AFTER THE OTHER . KUDOS TO YOU ...NOW IF I ONLY HAD MECHANICAL APTITUDE   MATTY D.

you still have the stock front end?

stu

Sounds like somthing I should fab up while I'm cutting out pieces for the lift.   I was thinking of just making a bolt on support colar to limit upward (reverse) movement.

Just a thought?  Why don't I hear of guys running Sammy steel carriers in kicks?   Sammy rear is alread 26 spline, front carrier & 3'rd is same as a kick...   You would have to fab the ear but this is a week link anyway...   I know that you'd still have the thin aluminium housing issue, but this is being delat with by the hybrids, Anvil, and xl-7...

I thought about that but thats still a weak link as far as i'm concerened(sp).  the "ear" would be stronger if you built one, but its still small.  when i get my custom front end done next winter i'll show and tell.

stu

Ya the housing is still the stock aluminum one.

I was going to buy a brand new steel housing rom the dealer, but they want over $300 for it.  I tried all the wreckers but its literally impossible to find a used steel carrier on the island.  

Mac found a good deal for me, but unfortunately its gonna take a while before it happens. So this is just a temporary patch until I get my hands on the steel GV carrier.  

 I've asked this before but never got a real clear answer. Is the GV axle housing and front diff a bolt in item?

I know that the GV 3rd member housing bolts right onto the sidekick axel housing.

I'm not sure if the GV axel housing will bolt right into the truck.  You may need to modify your mounts a little, but don't quote me on this.  

Hey kreg, wheres my Sig?  

Sounds sweet Cant wait to see what you came up with. When are you going to have it done and try it out?
Zig

I've asked this before but never got a real clear answer. Is the GV axle housing and front diff a bolt in item?

Not really a straight bolt in as you have to change the R&Ps because the GV has something like 4.4:1 and the Track/Kick 5:12, it varies between models but its still the same problem. Otherwise its a straight swap.

I was hoping to have it done today, but I fooked up on a measurement (every mans nightmare) and I'm going to have to pretty much re mold the ear so it fits.  


By the time I figured out that the ear wasn’t going to fit without doing a bunch more work I lost moral and went home. (Didn’t have anything to eat all day. Energy level pretty low)

Heh I walked into this thinking it was going to be an easy fix but I'm running into problems left right and center.

- First off, when I welded the housing last night the whole thing expanded and the pinion races fell out.  Had to pound them back in this morning, which was a pain in the |removethispart|@$$.

- Secondly, I forgot the backlash settings after I reassembled the front carrier, so I had to log on and search through old posts to find the right settings since I misplaced my Haynes Manual somewhere.

- Thirdly, as mentioned above. I found out that the ear was way off when we welded it to the housing. So I'm going to hack some of it off, re weld a new portion on top, then drill new holes.    

Hopefully it will be done tomorrow.  I may not go to work so I can get it fixed. Frustrating indeed.


Hehehe Here I am hoping to have my front end fixed, rear locker installed, finish my rocker guards, make a front skid plate, and rotate my rear axel with longer shocks, by Saturday.  

wow sounds like you have been working hard and will be that way till this weekend.  good job

stu

sounds cool kreg, what elese is left? almost ready for 4x4ing again?

was that you i passed today, it was on cedar road i waved but couldnt see who was drivin, it was either your or mac.

It was Mac, cuz my truck has been in the shop for the last 2 days.

Hehe it’s hard to tell them apart. The trucks are almost identical twins except for bumpers and tires.