I don't know if someone thought of this befor. But wouldn't it be easier and cheaper to make the hub mounting bolts the weak/shear point for the front drive line?
All you would have to do is replace the hub mounting bolts with weaker ones. This easy mod would work for ALL suzuki SUVs since they all have either a auto or manual drive hub. Or drive flange 99+ TrackVits.
What I am thinking of doing is finding the weakest bolts I can to replace them with. When they fail I will inspect the front diff for any cracks (2000 Tracker )!
If no cracks I will replace the bolts with the next up in strength. And go from there.
I would rather carry and replace a hand full of bolts than carry and replace a axle, cv's, axle housing, half shafts, or what ever else.
This is similer to warn hub fuses it just uses the bolts instead. And if your thinking it's hard to replace a broken hub bolt your in the wrong LIFESTYLE. A good cordless drill, some sharp bits, and a screw extractor is all you need if at all.  

shoot make it easy on yourself and:
1.make a jig to hold enough bolts for one complete repair at a time
2. use the jig in a drill press and pre-drill holes all the way through for an easy out
3.use  medium grade bolts, not cheap ones because when you drill holes down the center they become 50-60 percent weaker


my 02 cents

shoot make it easy on yourself and:
1.make a jig to hold enough bolts for one complete repair at a time
2. use the jig in a drill press and pre-drill holes all the way through for an easy out
3.use  medium grade bolts, not cheap ones because when you drill holes down the center they become 50-60 percent weaker


my 02 cents

This is a damn good idea! I tell ya, if a bunch of us could get ceo positions at Suzuki head quaters there would be some bad a$$ zuks rolling around.
The concept would be trail capability first and street second!

 sound's risky to me - wheels falling off - wouldn't the fused hubs sold by RRO be a safer solution? it's not just your life after all!

sound's risky to me - wheels falling off - wouldn't the fused hubs sold by RRO be a safer solution? it's not just your life after all!

WHeels falling off?????????????? ???
The hub mounting bolts have Notting to do with the mounting of the wheels on the vehicle! ;)
Sometimes the factory bolts fail and all you end up doing is replacing the hub bolts and continuing on your merry way to grand ma's house! ;D

you could experiment with removing different core sizes aka use different drill bits to achieve a selectable result. damn im supposed to b off work today

you could experiment with removing different core sizes aka use different drill bits to achieve a selectable result. damn im supposed to b off work today

Another great idea! Suzuki head quarters here we come!

 sounds ok i guess.  I think hub fuses would be better, but on the other hand you could now have spacific(typo) one made just for you truck and its tire size and everything.  I dunno  after some one else is the expermental mouse that tests this out, i will stay with my stock hubs.  lata Stu

sounds ok i guess.  I think hub fuses would be better, but on the other hand you could now have spacific(typo) one made just for you truck and its tire size and everything.  I dunno  after some one else is the expermental mouse that tests this out, i will stay with my stock hubs.  lata Stu

Exactly! Hub fuses are basicaly a one size fits all type deal. I'm not knocking them I'm just saying that you could customize the bolt strenght to your vehicle and wheel size.

In my oppinion I think the weakest bolts are too
strong to let go when needed, plus there are 6 of em
that need to let go at the same time, and the extraction
is going to be a pain, even with a drill and screw extractors.

All you new Suzuki Execs, build us a better/stronger driveline,
not a weak point to prevent weak link breakage.

IMHO
Darrin

 

In my oppinion I think the weakest bolts are too
strong to let go when needed, plus there are 6 of em
that need to let go at the same time, and the extraction
is going to be a pain, even with a drill and screw extractors.

All you new Suzuki Execs, build us a better/stronger driveline,
not a weak point to prevent weak link breakage.

IMHO
Darrin

Ok,   Don't I feel like the kid in the corner with the dunce cap on!
Know I know what the first guy that said hey lets build a zuk to off road in probably felt like.

The idea is what is important, keep thinking, that's
how mods and answers come about, there are good
solutions, and some that don't work out, but you
never know until you try.

Keep Thinking...........

Im new to the zuki world, but have been wrenching and wheelin for a long time. My 2 cents goes like this. What comes out easy in a controled enviroment, never acts like something that has been in the elements. The bolts might not be to hard to get out now, but wait till they have been dipped in mud, water, sand, ect.      Bad
I would just go with a hub fuse, easy easy easy to replace on the trail.

you might have to grind on the fuse itself to make it thinner in a few spots, I have heard that they are too strong for the stock zuk axels with 22 spline!