Did some searching and reading and didn't find a definitive answer.. So I will pose the question with full expectation of a flaming as I should know this answer..

so vitara and trackick T-cases are interchangable.. We all know this.

early kick cases are odd ball and don't work with gear sets. we all know this.

does anybody know if the fine spline output shaft of a trackick case will swap into a vitara case with a course spline output?

apparently 95 or 96 and newer trackicks also have course spline outputs..

the dilemma lies in the ability to use a TT SYE kit.. they only have fine spline SYEs.. no plans to make coarse spline..

so can a I buy a fine spline trackick output shaft and swap it into my vitara T-case?

They went to the coarse spline output shaft in 96. 
AFAIK, the output shafts interchange.  I don't know of any reason why they wouldn't.

There is an internal difference between a 93 Tracker TC and an 05 XL7 case.  I used a 03 GV output case with small output shaft and changed in the larger 05 XL7 shaft.
Both the GV & XL7 TC's have the syncro's in a different spot than the 93 Trackers.

There is an internal difference between a 93 Tracker TC and an 05 XL7 case.  I used a 03 GV output case with small output shaft and changed in the larger 05 XL7 shaft.
Both the GV & XL7 TC's have the syncro's in a different spot than the 93 Trackers.

What are you calling synchros?  I have never heard of a tcase having synchros.

The '98~'05 GVs and the early XL-7s have synchros in the transfer case - supposedly to permit SOTF between 2HI & 4HI - but to the best of my knowledge a '93 Tracker would not (a '93 Sidekick does not).

Oh, ok.  I am sure none of the 89-98 cases do.  I have had a few of them apart and never seen any synchros.

What are you calling synchros?  I have never heard of a tcase having synchros.

The collar that shifts to allow you to go between high and low range, or alternatively 2 and 4wd.  It's close, but you can't just swap parts from a 93 transfer case to an XL7 t-case in order to make it manual shifting instead of using the electric bit.

This is a good question / discussion!

-Eric

Did some searching and reading and didn't find a definitive answer.. So I will pose the question with full expectation of a flaming as I should know this answer..

so vitara and trackick T-cases are interchangable.. We all know this.

early kick cases are odd ball and don't work with gear sets. we all know this.

does anybody know if the fine spline output shaft of a trackick case will swap into a vitara case with a course spline output?

apparently 95 or 96 and newer trackicks also have course spline outputs..

the dilemma lies in the ability to use a TT SYE kit.. they only have fine spline SYEs.. no plans to make coarse spline..

so can a I buy a fine spline trackick output shaft and swap it into my vitara T-case?

Some of the shafts ARE interchangeable, but not back to the old trackick case.

well this was good enough reason for me to dive into making my own then.. I had a spare coarse spline driveshaft laying around so here is what I did...

took this part and cut all the crap off.. Dust ring flanges etc and chucked it up in our crappy japanese lathe at work..

then you get this:

then I bought a drive flange with the pattern that I wanted and cut it up on the lathe..

I tried to make them as tight a fit as I could.. I actually screwed this up and they are loose by a thousands or two....they got some wiggle.. Ideally I wanted this to be press fit and was planning to freeze the slip yoke and heat up the flange but oh well...next one...  Then I tig welded them together...(had someone do it.. )

do you think it will break? OK do you think it will break with a 2.5L Vitara V6, 4:1 t-case gears and 35 or 37s?
I don't know either but I guess we will find out..

so it's still a slip yoke but it gives me a flange to have some beefy drive shafts built without a slip yoke in the drive shaft which saves money.. If you wanted to you could assemble this with enough room to run a bolt through it and drill and tap your output shaft.. ...baby steps..

also this will not fit on the front output shaft.. I built a second one with fine spline slip yoke and the drive flange hits the T-case mount.. I am in the process of grinding and triming the flange to make it fit.. will keep you posted.. might be a couple months..



I did this with a junky lathe, and some harbor freight cutting tools.. this steel was surprisingly soft...

so there ya have it..

junk driveshaft - free
flange - 20 bucks
harbor freight lathe tools - really can't believe i list that...

couple hrs time on a lathe and 6 pack to get you buddy to weld it..

oh yeah talked to tom woods and he can build a CV driveshaft with their 1310 u joints with no slip in the shaft for right around 300 bucks..

Looks good.
Did you chuck it back in the lathe, once it was welded, to see what the runout was/is?