Suzuki Vitara / Tracker Front Differential Teardown

A close look and explanation of the 4wd actuator that engages the 4wd inside of the front differential. This is the actuator that is engaged via the air pump that sits behind the front bumper. The pump is one of the most common failures I see with 4wd not working.
For more pics and details visit: www.diymetalfabrication.com/v...
I had welded my actuator within the front diff in the engaged position but broke it last time I was wheeling going up a very steep hill under full throttle. This is the teardown of me seeing how it works on the inside so I can fix it better next time.
The same design was used in all of the Chevy Trackers, Suzuki Vitara, sidekick and probably others I'm not thinking of.

[@SjoerdV83]

Thank you for this explanation, now its clear to me how the diff engages the 4x4. Learnt a lot👍🏻

[@diymetalfabrication]

Glad it helped!

[@Ezekiel-OffRoad]

About a year ago I Came across your webpage and welded my grand Vitara/ zr2 tracker haven’t had an issue yet and I do a lot of hard off-roading too A lot of sandhills here in Michigan haven’t had an issue yet. I used a 180 amp mig And put some heat to it I filled in the hole area Of the cutout did three or four passes then ground the surface smooth so there was no interference with pinion gear

[@jamespeters3907]

Great video. I currently have my front diff of in order to reseal the engine oil pan. I thinking about also welding up the front diff before it fails. 🤔. Your drill and make plug welds seem solid.

[@diymetalfabrication]

Go for it! Let us know how it goes.

[@johnrussell3235]

I'm currently about to change out my 2003 Tracker front housing, I broke my Aluminum 1 and replacing with another Aluminum, wishedi could get a Steel... I'm told you can use a plastic zip tie on the collar instead of welding. Seems odd to me. Thanks for sharing your experience 😊 🙏

[@diymetalfabrication]

Those steel diffs are hard to find and $$$. Luckily mine hasn't grenaded yet, I only broke the pinion mount for which I have a fix detailed out on my blog for how to fix: www.diymetalfabrication.com/vitara-tracker-diy-front-differential-pinion-mount-fix/

[@Zewestcoaster]

Did you weld all four recesses for the sliding collar or did you only weld the one? (that you show as being broken)
Now that it is all torn apart, it would almost seem like you could drill and tap grade 8 bolts through the two rotating housings to pin the two halves from rotating within each other.

[@diymetalfabrication]

I welded all four recesses. It is possible to drill through the differential case, but it is NOT possible to drill through the inner carrier part that holds the spider gears. I tried to drill into it and barely scratched the surface, it must be some kind of super hard steel.
What I eventually ended up doing was drilling 8 holes around the perimeter of the differential case the plug welding the inner carrier part to the outer differential case. I have been beating on it ever since without any issues.

[@Zewestcoaster]

@@diymetalfabrication Thanks for the reply, Welding cast iron is a little trickier. I was likely heading toward the same result as yourself with the broken welds until I saw your video. I may end up taking this in to a shop that has a bit more experience at welding cast than I do....

[@richardmarsden6516]

Do you think if you welded the outer part of the diff you would be able to fit a lock rite locker to it?

[@diymetalfabrication]

No, I don't think there are any lockrites made for 98 and up models. Honestly, with the aluminum case, I don't think I would put a locker up front even if they made one for it. I am able to get most places with just a locked rear.

[@masonbaylorbears]

I just bought a 2002 tracker that has had this done before i owned it. Its crazy loud and bumps a ton when turning. Is this an offroad only mod? Would it be too hard on it to drive on the road at any higher speed?

[@diymetalfabrication]

Hmm, sounds like something might be wrong with it. Might have come partially disengaged. I know your post was a while ago, let us know what you found out!

[@pablopicapiedra7061]

Hola amigo lo saludo desde argentina , queria preguntarle si a la fecha a podido solucionar el problema del diferencial delantero utilizando este metodo con soldadura , le pregunto por que me a pasado lo mismo que me quede sin traccion en el eje delantero de mi gran vitara año 2000 2.5 cc, y aqui en argentina se complica conseguir repuestos dado a la economia actual le agradeceria su respueata para orientarme

[@diymetalfabrication]

Yes, it can be fixed this way. Make sure it gets welded good because I broke the first set of welds I did and had to take it apart to weld up again. I have a whole post about how to do it here: www.diymetalfabrication.com/vitara-tracker-permanent-4wd-differential-actuator-fix/

[@robormiston2841]

That's a factory limited slip I think.so when it's pushed in its full locked.

[@diymetalfabrication]

The front diff on these are 'open' differentials. What the teeth do is engage the 4wd (by engaging the spider gears inside the diff) because the 2nd gen Vitara / Trackers don't have manual hubs.

[@wahairiwahi2458]

it good if i weld front diff with manual hub lock?

[@johnwarren5938]

Is there any way to fix the pump?

[@johnwarren5938]

Great video by the way, very informative

[@diymetalfabrication]

I mean, ya it could probably be resuscitated back to life or replaced but I didn't want to mess with it. I ended up welding mine engaged.