Does anyone know of a way to strengthen the aluminum front diff housing on a kick, to help prevent breakage? I am about to install two used diffs with lower gearing into my auto tracker, and am installing a lockrite into the rear, and would like to possably do somthing while they were easily accessable. I'd like to go with the calmini anvil, but $(i just spent $450 on a running parts tracker) and the fact I am using a 2.5" rro susp lift not the 3" calmini prevent me from going that route. Thought  maybe I could do a bit of prevention if that is possible. Thanks for any input.

check this out

http://www.zukiworld.com/month_090103/feature_sidekickdrivetrainimprovements.htm

Thanks Chet.  I was trying to keep costs down since I just sprang for the parts tracker. Maybe I can sell off some of the leftovers to pay for the other stuff I need. All I wanted were the front and rear gear sets and transfer case. The rest is a running 8 valve 1600 w/ 5 speed if anyone needs anything. 

I've been beatin the hell outta my tracker (auto with 5.12's swapped in, locked front+rear). I figure it's had 16-18 HARD runs this year, and I've YET to break it ... I think my tcase mount might be "worn out", a CV up front has boots torn, steering is pretty dang loose now ... but still not broken! Hell, I'm going to drive to/from a snow run this weekend, and not worried.

I plan to beat this sucker to breakage, strip out the lockers and put it into another rig for next years abuse. I'll sell off a nice running 8V engine, and still have parts to strip.

To me these are "disposable" wheelers if you're into really beatin on stuff.

And SnoFalls doesn't mean "disposable" in a bad way....  It's just easier sometimes to get another one instead of rebuilding and rebuilding over and over.

And SnoFalls doesn't mean "disposable" in a bad way....  It's just easier sometimes to get another one instead of rebuilding and rebuilding over and over.

Buy-it, Build-it, Beat-it, Part-it

 ;D 

  thanks guys! I guess I'll just keep the 92 around as a parts car, and I'll have an xtra diff case should  I brake one. What to do with that good motor and trans though?

I'm looking for a battery hold down and a bit of hose and a connector for the passenger side windshield sprayer.  If you'd part with that stuff from your parts vehicle I could help your quest along a bit.

I put a strap over the nose of the front diff and bolted it to the crossover.  Even though I now have an Anvil, I never broke the front diff.

Also I have a calimini 3" lift, and the nose of the front diff rests on the cross over.  So, in a forward direction the nose is resting on the cross over and in reverse, the nose is held down.

Limiting the movement, I believe is what kept it from breaking.

Good luck

Eric

check this out

http://www.zukiworld.com/month_090103/feature_sidekickdrivetrainimprovements.htm

WOW! something useful to know for my 'Kick.

This may be obvious, but does this also mean that I can take a Grand Vitara third, swap out the 4.62 guts in my spare aluminum TracKick housing into the GV housing and then bolt it right up to my '88 Samurai front differential?  This would mean that I don't have to do a R&P swap --  just a complete unbolt/bolt and swap.

Right?

Bueller...

Bueller??
 

This may be obvious, but does this also mean that I can take a Grand Vitara third, swap out the 4.62 guts in my spare aluminum TracKick housing into the GV housing and then bolt it right up to my '88 Samurai front differential?  This would mean that I don't have to do a R&P swap --  just a complete unbolt/bolt and swap.

Yes or possibly no 
I had my Track/Kick 5:83s built into the GV housing, others have had the Track/Kick diff assembly swapped (to match 22 spline shafts). The Sammy and Track/Kick front swap so it should all be possible. When you fit the diff assembly into the GV housing you will have to reset the pinion preload so you will need a new crush spacer.

So it looks like a matter of cost then.

Unless I can get a GV third housing cheaper than I can get a pin-retaining can for the Samurai front third, the cost is a wash.   I bet I can get a can cheaper...

At least I know what to get to beef up the front of my '93 Kick.

Thanks!