This is good news for GV with cast diff. I heard from Suzuki that 2004 XL_7 diff is a  reinforce design. More tough, and more reliable.
This is the pic of 2003 XL_7 diff.

That's the one. If you notice the line under the housing coming off the crossmember, that the pressure line which engage the front differential to work.
I haven't gotten to the diff, but from my understanding, this engages a collar on the driver's side, which then engages the spider gears which in turn spins the axle shaft. From your picture of the '04, there is a motor on top of the diff and is integral of such. To add, it looks electric.

As for the better design, why didn't they use only one CV axle shaft for it's design? This would save on manufacturing, installation, replacement, etc. costs.

Haha........Calmini does provide a drop bracket for the frame, but still with some problems. So I didn't use it. So I use adjustable sleeve for the track arm.
Actually, since I changed the Calmini kit, there are some problems. As below:
1. No support ability for the front and rear coil springs.
2. Bad quality front absorber(Made in Mexico)
3. Front diff drop bracket doesn't fit to the space.(Drop too much and touch to the frame)
This is the Calmini and original rear coil spring comparison

This is the final rear coil spring(The black one, 5" longer than original )

1. Assuming you are talking about the coil retainers, for the rear spring with it's axle base, you could drill through the center  of the base and bolting flat steel to retain it. You could also add a bump stop pad on top of that to keep the tire off the body.
For the front, it's not as easy to do with the stock cast control arms. With the Calmini arms, you could do the same as the back.
3. Maybe the bracket didn't fit well enough due to the new design front axle housing.

As for the rear spring, who is it? what do it fit? where is it available (I know you are not in the US)?

Then, I've got to wonder what those bolts on the cover are for? My design doesn't have a cover to it. The rear portion is an integral part of the entire housing.

jagular7, I'm sorry that I couldn't get what you said. Could you point out where? Thanks!

No you did get the picture of the front axle. Thanks.

You wouldn't happen to have any pic's of the front wheel opening and what you did to make them fit the 245's
George

This is good news for GV with cast diff. I heard from Suzuki that 2004 XL_7 diff is a  reinforce design. More tough, and more reliable.
This is the pic of 2003 XL_7 diff.

The Steel unit we used for Hutch's Sidekick looked just like the aluminum housing...

From the archived ZUKIWORLD Article: http://www.zukiworld.com/month_090103/feature_sidekickdrivetrainimprovements.htm



I would speculate that JoeJoeKuo is different than what we are used to seeing because it is not made for the NA market. Notice the actual badging is different too saying "Grand Vitara" instead of XL.7

-Eric

....snip....
I would speculate that JoeJoeKuo is different than what we are used to seeing because it is not made for the NA market. Notice the actual badging is different too saying "Grand Vitara" instead of XL.7

-Eric

Yah, I was thinking that also, but then, how many plants would Suzuki have to be making different vehicles for the same model for the different parts of the world?
Then come to think, the ECP gets input for the pump operating to be in 4wd mode, at least in my '02 -7. JoeJoeKuo's looks like its an electric motor right on top of the diff. I wonder if the electric's are the same.

It's really too bad that the manufacturer didn't move the diff housing centered more to be able to run the same cv axles on either side. The ds is not parallel with the centerline of the -7 so there little room to do. I believe Calmini's Anvil does this to make room for the same cv shaft.

Actually, go to JoeJoeKuo's webshots website and look at his front diff setup. From one side pic, it looks like it a a bunch of pieces bolted together. (Pic DSC03663 on 5 page.) The driver's side axle tube bolts to the diff housing, then front and rear portions bolted together, and then passenger's side which is also the mount.

to add something.... I have a test in 4wd and off road magazine from last year where they test a 02 XL7 and Broke the front alum diff. Cracked it off roading it.. I *think* Suzuki knew it was too fragile. Thats why the 04 change completly.. And if ya notice there is NO mention of this on am 04 brochure.. It was more or less a KNOWN needed improvement. Suzuki did not need to boast that fact.. I think ALL 04's have this change .. no matter where it is destined to
Im sure its fine for our 4wd snow driving tho:)
Frank

Go off-road
This place is located in the north of Taipei. We call this place : Tough guy MT. Enjoy the pic.