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GV 3d-1600 frond diff mods... any help

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Offline gv1600

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GV 3d-1600 frond diff mods... any help
« on: December 20, 2005, 10:34:51 AM »
Hello to everyone here,

I,m from greece and i own a GV 1600cc 3d 2003 model with a calmini 2,5'' setup and i want to make an upgrade in my frond diff.
I want to put the iron/steel housing and the iron/steel third member in my car!
some photos in order to make you understand how my stock frond diff is now.




i 've read most of the articles in here and also searched for posts about that mod in vitara's or GV's frond diff but i want some help (if possible) to make me understand a few more things.....

as i understood vitara users use a third from a GV 2500cc MT 1999-2001 model , right?
and a housing from an XL-7 (dont remember the excact year).
A friend of mine used in his vitara the whole frond diff from a GV 2500cc 1999 (as he remembers) and fitted just fine, with no mods at all!

So as a GV owner, what housing and third member do i need to make that mod in my car too?
Will a full system  (housing+3rd) from a GV 2500cc 1999-2001 model be fit in my car?
Will it be any problem with the housing or anything else??
Will the axle shafts be ok using that housing and 3rd??
I have to say here that i,m gonna try to put a 5,83 R/P.... so include that too when you want to write something about that mod!

Thanks in advance, Vasilis. :)


« Last Edit: December 20, 2005, 10:43:45 AM by gv1600 »
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Offline wildgoody

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Re: GV 3d-1600 frond diff mods... any help
« Reply #1 on: December 20, 2005, 10:44:35 AM »
It's is a steel axle housing, just like the alloy
one but made of steel, all axles and gears
will fit and work.

5.83 gears are hard to get now, at least the
rear 12 bolt ones are, not in stock or production
right now, and no hard dates as to when they
might be available

PS. where in Greece ?  Grvit is over there too,
do you know him?

Wild
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Offline blacknight

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Re: GV 3d-1600 frond diff mods... any help
« Reply #2 on: December 20, 2005, 10:47:04 AM »
You want a 3rd from a GV 99+ and the housing  can be from a GV or XL-7.  The housings are the same just the 3rd's that aren't the same.  Not to say that an  XL-7 3rd won't work you will just need to drill a new hole to mount it.

George
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #3 on: December 20, 2005, 10:59:45 AM »
Thanks for your answers,

I wasn't sure if the housing must be from a GV 2500cc 1999-01 or from an XL-7, and also which 3rd matches excactly to the place that the alloy 3rd is now.
I'll prefer the 3rd from a GV 2500cc for sure than from an XL-7 and have to drill.
As for the 5,83's.....i know i have to try hard in order to get them, but its in my mind too :)

I,m from Heraklion-Crete, but i know GRVIT.

PS. has anyone here any pictures with that mod in a GV like mine?? just to check... :)
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Offline cj

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Re: GV 3d-1600 frond diff mods... any help
« Reply #4 on: December 20, 2005, 12:23:38 PM »
Look at the pic of yours and think steel instead of alloy and that's how it looks. If you can find a late 2003 and on GV or XL-7 auto it should be steel too. Definately look for the GV instead of the XL-7 as the GV needs no mods to fit. All you will need to do is get your ring & pinion swapped in.
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Offline locjaw

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Re: GV 3d-1600 frond diff mods... any help
« Reply #5 on: December 20, 2005, 12:36:54 PM »
how did you get the winch in the stocker bumper? that is slick looking 8)
jason
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #6 on: December 20, 2005, 02:55:08 PM »
Quote from: cj on December 20, 2005, 12:23:38 PM
......If you can find a late 2003 and on GV or XL-7 auto it should be steel too. Definately look for the GV instead of the XL-7 as the GV needs no mods to fit.

So you say that a late 2003 GV 3rd will be ok too??
I have to be at the local dealer and check the list of the 3rds and the housings too.

And another question that came to my mind right now.........
If i use that GV's 3rd, can i put a carrier from a vitara (10bolt) in order to install a locker someday later? or do i have to use mine again?

As i understood, the frond carrier of the GV's that use presure to block/move the frond axle shafts, has something in there and i ve heard that is not really good!
Something like a small "ballon" which works with presure when we engage 4x4, is that correct?
Or i,m wrong?

Quote
how did you get the winch in the stocker bumper? that is slick looking Cool
jason

Its a T-MAX 6500 lbs at its stock plate but after a few mods it was ok!
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Offline Rhinoman

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Re: GV 3d-1600 frond diff mods... any help
« Reply #7 on: December 21, 2005, 09:01:12 AM »
You can use the Vitara carrier, there is an article on here showing how to do that, or you can fit the R&P of your choice into the GV carrier. I went this route with my Vitara and fitted the air pump from the GV. If you fit the Vit carrier then you will want the later one with the 26 spline side gears. I couldn't get a 12 bolt rear 5:83 R&P so I used a 10 bolt rear carrier from an earlier Vit.
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #8 on: December 21, 2005, 10:49:43 AM »
Quote
.........or you can fit the R&P of your choice into the GV carrier.

Thats excactly the point that i,m afraid of!
If the 5,83's couldn't fit into my stock GV carrier (front+rear) and then i have to get a Vit 26 spline carrier for the frond and a third with carrier for the rear  :-\
I also heard the the air pump is not so good and a guy here had probs with it...... any ideas about that??
what would be the best for me.......keep it stock as it is now, or change it with a Vit carrier 26 spline without air pump??

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Suzuki GV Calmini 2,5'' - Full Steel V6 Frond Diff - 205/80/16 KL71 -
4.24 t-case - T-Max 6500 - VTTR Snorkel - ProTrack Air-Lockers F/R
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Offline Rhinoman

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Re: GV 3d-1600 frond diff mods... any help
« Reply #9 on: December 21, 2005, 01:40:31 PM »
Quote from: gv1600 on December 21, 2005, 10:49:43 AM
Quote
.........or you can fit the R&P of your choice into the GV carrier.

Thats excactly the point that i,m afraid of!
If the 5,83's couldn't fit into my stock GV carrier (front+rear) and then i have to get a Vit 26 spline carrier for the frond and a third with carrier for the rear  :-\
I also heard the the air pump is not so good and a guy here had probs with it...... any ideas about that??
what would be the best for me.......keep it stock as it is now, or change it with a Vit carrier 26 spline without air pump??


Well I know they fit in the front. I was typing in a rush earlier, you have a GV so you have the 26 spline shafts :-[. I understand your concerns. I had replaced my complete front axle assembly after I broke the original, the replacement was 22 splines (original was 26) I ended up having to buy another front third because I was told I needed the Vit carrier and a rear third too. Then it turned out that I didn't need the front after all because the R&Ps fit in the GV afterall. It was worth all the trouble though as 33s on a stock 8V suck, the 5:83s are a big improvement. That said I was a little disppaointed with them at first as it wasn't as big an improvement as I was expecting but it still goes up hills one gear and 10mph faster.
I don't know about problems with the air pump, what sort of trouble did he have, a pump problem or a leaky pipe? The mechanism looks as strong as any locker. If its anything like the Jimny then removing the air pump will give you a fault code as its all wired throught the ECU so the Check Engine Light will be on. I don't have that problem so I wired it on a switch so I can run 2wd low. Personally I would use the GV assembly but I would fit free wheel hubs too for those times when you bust a driveshaft or similar.
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2000 Vitara 1.6, 3+3 Lift, 33"MTs, 5:83s, LWB brakes, Winch, Snorkel, Safari Rack
1986 SJ413K PickUp, 1.6L conversion.

OBD1 - Full diagnostics on a PC/Laptop: http://www.rhinopower.org
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #10 on: December 22, 2005, 06:37:30 AM »
Hi,
yes, i have 26 splines at the frond.
I was just wondering if the 5,83s would fit into my stock carrier but as you say now its not gonna be a prob at all!
That's the good news for me :) :)

Now about the problem that a guy here had was that when the turned into 4L and the 4x4 light was On, the frond wheels didnt engage??!!
He went it for a service in the frond diff and they told him that there was something wrong with the "ballon" (he named it like that) in the frond diff and the axle shafts couldn't engage.
They changed it and then it worked fine.
Dont really know if he had a prob in the pump or at the air-line (leaky pipe??) which goes into the 3rd.
Anyway, i found some photos of a GV stock air frond diff and after i saw them i understood what u said before........ that it looks strong enought.
So most of what i was wondering about is explained to me now!
i would use my carrier as u said (if finally 5,83s fit in) but change the 3rd and maybe the housing too.
I also have free wheel hubs and they are working fine till now.
Thanks Rhinoman for the info and help  ;)
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4.24 t-case - T-Max 6500 - VTTR Snorkel - ProTrack Air-Lockers F/R
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #11 on: December 24, 2005, 12:39:56 PM »
Hi,

Finally i managed to broke the alloy housing of my GV  :'( :'(.
I couldn't believe that it's so easy to brake it...... allthought it was a very easy normal obstacle for me and my style when drining off road.......   ???
So now i,m gonna get the full set of GV 2500cc in the next days.

I' ve been to the local dealer and asked about the 3rd and the housing from a GV 2500cc.
Nobody here in my town made that mod till now (as i know) so, we ve found codes for the housing and the 3rd too, but the first 2 codes are from SQ625-T1 M/T, and the other codes are for SQ625-T3 M/T..... that last one refers to the earlier GV 2500 (new interior/facelift?) and i think its from 2003 and on.
Does anybody here has the codes of the parts that i need in order not to make a mistake when ordering the stuff?

Thanks in advance,
Vasilis.
« Last Edit: December 25, 2005, 09:52:27 AM by gv1600 »
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4.24 t-case - T-Max 6500 - VTTR Snorkel - ProTrack Air-Lockers F/R
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Offline blacknight

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Re: GV 3d-1600 frond diff mods... any help
« Reply #12 on: December 26, 2005, 01:29:08 PM »
It might refer to the oil fill plug on the front on the diff.  I think that in 02 or 03 they moved it up higher.
George
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Offline gv1600

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Re: GV 3d-1600 frond diff mods... any help
« Reply #13 on: December 26, 2005, 01:58:03 PM »
Hi George,

i wish if that is the only difference between them!
Tomorrow i,m gonna make some phone calls and check out the codes i need!
Thanks anyway for the info.
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4.24 t-case - T-Max 6500 - VTTR Snorkel - ProTrack Air-Lockers F/R
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mudfkr

Re: GV 3d-1600 frond diff mods... any help
« Reply #14 on: December 26, 2005, 02:43:48 PM »
Hi GV1600,

I used a steel diff from a 2Lt diesel Vitara to put into my 1600 Escudo which would bolt up to your GV as well but it doesn't have the air fitting for the air actuated Carrier that the GV uses, meaning you'd have to put manual hubs on it and find a 26 spline standard carrier  or use an ARB locker to get around the problem  ;D.

Here's the parts that I used if they are any good for your set up that you want.
The Chassis code here in New Zealand for the model I used is SV620-3 E01_106.
The third member part # was 27450-78E00 Sorry I don't have the part # for the banjo housing but you should be able to get it from the  chassis code.
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