I managed to blow up the Goblin's front diff today. The pinion carrier snapped completely off the whole way around the pinion, allowing the housing to swing free, hanging from the end mounts! For now I think I'll just swap Silver's diff into the Goblin while Silver awaits the frame shop, but then I think I want to try to upgrade it if possible. What year/make of donor vehicle do I need to salvage the pinion carrier out of that will fit the stock Tracker housing and the stock Tracker diff, while being steel and stronger than stock? Any help would be appreciated. I searched and found some info, but most of it involved adding the Anvil, which wont fit without the Calmini 3" suspension kit and I can't afford right now, anyways! LOL!

That magazine article had you out showing off ehh ??
 

Wild

Oh, any steel 3rd will fit the housing

I thought I read somewhere about GV's and XL7's having different mounts to the crossmember Also I read Zig's Anvil Install article and he removed the tie-rods and struts. It looks like I can sneak it out of there by just unbolting the driveshaft and left side cv flanges from the housing, then removing the housing mounting bolts. It should drop right out, dis-engaging the right cv after/as I drop it, right? Or is there something in the way?

Well it's easier to remove the whole thing
(housing and 3rd member) at the same time,
and to get it out the center link is just in the
way to keep it hung up.

Drop the center link, and it will come out much
easier, the aluminum front assy is heavy enough,
the steel one is going to be a 2 man job, just so
you don't get squished if it gets out of control 

Good Luck
Wild

Cool, thanks for the info and advice!

I thought I read somewhere about GV's and XL7's having different mounts to the crossmember

So what all makes and years of vehicles have the steel third carrier? And what about the mounts to the cross member?

I don't remember reading about the years
that fit, I thought the GVs all fit the Track/Kick
front housings, you might need to get new
mounts (rubber) but I don't know

http://www.zukiworld.com/month_020103/feature_frontendupgradeswithhagen.htm
From which I recall. THe steel front 3rd was from a 99-2001 5spd GV
My front snout was differant so I had to redrill the holes for my mount.
Still working tho.

If I get the steel third from a 5sp 99-01 GV, would it have 5.12's in it or will I have to transfer the diff from a similar tracker?

If I get the steel third from a 5sp 99-01 GV, would it have 5.12's in it or will I have to transfer the diff from a similar tracker?

it would have 4.3 ratio's.  you use any year gv, ive got an 03 in the front of my 89 swb vitara

So I just want to be sure of my shopping list here. If I want to end up with a steel housing and 26 spline shafts, I'll need:

1. A steel full housing from any year GV(housing and third case)
2. The right cv, left inner axle shaft and diff (everything inside the housing) from a 95&up 5 speed Track/kick(so I get the right 5.12 R&P as well as 26 spline shafts)

And I'll need to have the diff with the 5.12 gears installed into the GV housing so the mesh and backlash is set correctly.

Then I just put it all together and bolt it into my Tracker, right?

Am I missing anything here?(aside from the front ARB Air Locker I can't afford )

I believe the 96 and ups have the 26 splines.
and you will need to find a rear sammie center section machined out to fit the kicks axle.
THats also, I believe, to be avilable from Hawks Suzuki.
I got mine form a friend who installed an ARB up front and didn't need his anymore.
BTW. The Sammies rear center section has 4 spider gears where the kicks only have 2.
And since youll be running the 5:12s, you'll also need the pin can thingie that holds the spider gears pins in. (5:12s are too small to hold the pins in)
Cuase, If you broke yours, the spider gears will be bent ever so slightly and cause problems later.
It's hard to tell but learning by my freinds mistake. He's had to replace his front gears more than once to discover that problem.
Quote from article:Front end modifications for the Suzuki Sidekick

You will need a ring and pinion retainer sleeve kit. This can be purchased from Hawk Strictly Suzuki or Spidertax. This kit is designed to put a Tracker/kick ring and pinion into a Samurai axle.  This kit is a two-piece kit. Since we are putting a Samurai carrier in a Tracker/kick housing, we will only need the barrel from this kit. The barrel is to hold the pins for the locker in place so they do not hit the pinion. Assemble into the Steel housing.

Digger,
The steering parts were removed to fit my anvil into place and to avoid having to work the parts in and out of my vehicle. A few bolts, all of that junk is out of your way and it gives you ALOT more room to work

The XL-7 mount is what it shown in my article, and a GV mount is like your kick mount. The only mod needed (if you go with an XL-7) is the crossmember needs mounting holes drilled in it)

I may be wrong, but unless you are going to do a locker, I believe that there is no need to get a Sami carrier, your Kick parts should bolt right into the GV/XL-7 housing. However, if a locker is on your list you will definately need to call hawk and get you one.

Zig

I had my 5:83s dropped straight into the GV steel carrier

For weight considerations, jump into the XL7 section. I swapped out my broken aluminum housing for a steel housing. I had to get a new set of 5.13s, but from articles, looks like I could have used any 7" overall diameter ring gear/pinion set. Add a locker if you prefer.
At the Melt, I compared my inner long shaft of my XL7 to Bill's Tracker model. It's ~1/2" longer overall with the same 3 point mounting flange.

I did manage to man-handle the 3rd member and axle housing in by myself. You just have to have your head under the tranny and use your legs to help maintain the balance while you put the bolts of the frame mounts in. Let the pinion rest on the crossmember.

Good luck.

So basically I need just the complete housing(steel) from a GV and the internals(diff, left inner axle shaft and right complete cv shaft) from 96 and up track/kick 5 speed and I'll have a full steel housing with 5.12 r&p and 26 splines that will drop right into my 93 Tracker, right?

Why do I need a machined sammy center section? Or is that if I put in a locker?