That right-side CV is loose on my GV and it has only 4000km on it.  I assume it's "normal" but what sort of design is that?

When you say loose how loose are we talking here.  If moves a little say 1/8" your OK there is some play in them. It's just a poor design with short axles stub that goes into the diff.

The part that I was talking about is the drive staft from the t-case to the front diff.  they have been know to rub on the exhaust pipe. Where they come down from the passanger (US) side and cross over to meet up the other side.

George

MANUAL HUBS!!!! It seems redundant to have a disconnect at the hub and the diff but to prevent premature wear of the cv-shafts and the diff seals, the best thing to do is keep the suckers from spinnin.  Calmini sells a set and I'd bet that Sammy or tracker/kick units would work too.  I'm currently swapping over because I don't want this to happen.  Then I'll just fill my dif up to the factory setting.

Tracker/Kick/Sami hubs bolt right up to any 99-05 GV/Vitara/XL7/Tracker.

Ok,
So I just want to get some clarification on this refilling the diff. I just replaced all fluids in the front and rear diff as well as the transfer case. But I had the vehicle on a level surface. Should I put it on some ramps and put more fluid in the front diff?

Thanks Much

Most likely if it is a 99-01 you should.  I just e-mailed you the TSB right now.