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Air actuated front diff delete problem

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Offline Browning

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Re: Air actuated front diff delete problem
« Reply #5 on: October 09, 2018, 01:41:07 PM »
Looks like you used pieces of ready rod and welded over top? I would do it a little different but totally get what you're saying about the stupid air system! I'm contemplating it for sure, as for the other suggestion of re-gearing I can't find parts on the pumkins! Only lockers and phantom LSD add on's ....
I like tight lines, big racks and sweet lines, I’m just a sofisticated Redneck!

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Offline beagle..t

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Re: Air actuated front diff delete problem
« Reply #4 on: September 29, 2018, 06:56:28 PM »
easier way is regear
new rig aka "the mule" 2002 tracker
V6 swap auto  ,2 dr ,2" BL,2" jeffs kit 512 gears warn hubs and 30/9.5/15 BFG AT

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Offline MexicoMatt

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Re: Air actuated front diff delete problem
« Reply #3 on: September 25, 2018, 05:15:30 AM »
So after a bit of thought I realized that the MIG welder may not have gotten penetration on the case hardened steel. Out came the diff again and lo and behold sure enough every one of the eight tack weld had popped. So we improvised redneck Style and added some chunks of Steel to lock open the actual actuator ring. Now to test it.

A couple of pictures of how I fixed it. I know the welds look terrible, I am definitely not a welder.

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Offline MexicoMatt

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Re: Air actuated front diff delete problem
« Reply #2 on: September 20, 2018, 06:27:34 PM »
So after a bit of thought I realized that the MIG welder may not have gotten penetration on the case hardened steel. Out came the diff again and lo and behold sure enough every one of the eight tack weld had popped. So we improvised redneck Style and added some chunks of Steel to lock open the actual actuator ring. Now to test it.

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Offline MexicoMatt

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Air actuated front diff delete problem
« Reply #1 on: September 12, 2018, 08:06:34 AM »
Hi there, first post. I did a search and only found 1 item of note so I thought I would start a new thread.
I lost four wheel drive and decided that the air actuator was too unreliable for what I want to do. This is all on a 2004 Suzuki Grand Vitara automatic. I pulled out the front differential put air to the actuator and then tack welded inside The Notches of the differential. While I was in there that's all I could see moving and I assumed that's all I needed to do. Well lo and behold I put it all back together and I still don't have 4-wheel drive. When I did the install I also put in a set of manual locking hubs. To ensure that those weren't the problem I uninstalled them and put the stock hubs back on. Still no 4 wheel drive. I jacked the back end in the air put it in four-wheel drive and put it in Drive. Nothing. The front drive shaft into the diff is spinning but the front wheels are not. My question is this, is there something else internal that needs to be welded? I'll  I attach pictures of my work.