Build Bulletproof IFS: Geo Tracker XL-7 Steel Front Differential Swap Tech

Aftermarket4x4

Aftermarket4x4

My Zuk’s HARD to Swallow!
Joined
Jun 20, 2020
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2130
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Loc
VA
Since I’m working on a 2006 2.7 V6 swap in to my 1995 2 door Geo Tracker why not bulletproof it by installing the XL-7 steel front differential. I read on the internet it bolts straight in … well as you’ll see that’s not exactly accurate!
Stock front diff:

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The factory aluminum Tracker diff with the XL-7 steel diff for comparison:

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Rough measurements show the 2006 XL-7 steel diff is approx 3/4 inch wider than the Tracker diff, but we will try to make it work.


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The XL-7 driver mount cannot be used but the Tracker mount bolts right on the in the same location so I hung that side then aligned the center diff mount on the lower crossmember and luckily the holes lined right up.

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Drivers side CV is the correct length and bolts right up to the XL-7 differential flange.

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The passenger side mount was a different story. It was actually off by about 2 inches and hits the underside of the frame.

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I pulled the pass side mount off of the diff which actually fully encircles the axle shaft, holds the seal and is also the bearing retainer so it cannot be simply swapped with the Tracker mount like the driver side.

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Factory Tracker mount nowhere near close to fitting.

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My solution was to cut the mount completely off of the rest of the flange area leaving a flat surface that can be bolted back to the diff and build a new bolt-on bracket.
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Leveled out the frame then leveled the diff and took a few measurements and started building.

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The new custom offset bracket was built out of 3/8” steel using the original rubber bushing with triangular gussets welded to the 3/8” plate. Here’s the finished product:


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Geo Tracker 26 spline CV shaft fits right in!

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Next step is the 2.7 V6 swap … Stay tuned!

Sean (still testing the limits of Japanese technology!) DeVinney
AFTERMARKET4X4
 

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Spy pics! 2.7 V6 installed and she’s got about 3/8” - 1/2” to spare between the pan and the steel diff. It’s about the same between the drivers side oil pan and the front crossmember.

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Trying to remember to update this thread as I’m farther along than this so here a few pics.

XL7 rear end installed:
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Custom upper Y-link and upper mount directly on top of the housing w/ 1” rebuildable Johnny Joint.
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Put a set of 31x11.50 Swamper rollers on her to get a better idea of size and stance. The rear is 2+ inches wider so the rear tires stick out more. I’ll be ordering 1.25” spacers for the front.

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Still waiting on custom driveshafts and a few other items before she can move under her own power.

Daily Wheeler V6 swap write-up coming… slowly… until then plz just watch the build on my YouTube channel:

youtube.com

Zuki Spec

This channel is mostly dedicated to the hobby of 4-wheeling, Tough Truck off-road racing, Rock Crawling events, trail riding, and other similar outdoor 4X4 sports. Most of my favorite vehicles are Suzuki’s and Toyota’s so the majority of the video's will feature modified and some heavily...
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The XL7 has a bigger R&P, but otherwise any advantages? I assume they dont have stock ratios as deep as a kick?
 
The factory 04-06 ratio is 4.30 which is fine for this build since it’s on 31’s and more of a daily then an off-road vehicle plus the Tracker is 1000 pounds lighter than the XL-7. There’s no other gearing options that I know of for these but I really haven’t researched it much. Biggest advantage to me is overall strength of that front steel diff vs. the Tracker aluminum diff and I was also told by someone in another county the 04 on up XL-7 rear end has larger shafts closer to that of a Toyota axle. I haven’t pulled one apart to verify yet, but will at some point. The rear does also have much larger drum brakes as well which compliments the larger 4 door Tracker front brakes I’ve installed.

Still waiting on driveshafts… but she’ll be driving… soon!

Sean
 
Protrack.gr in Greece makes air lockers for them … but if someone made gears for them that would be :smokin:
 
350TacoZilla said:
fixed
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Wheel spacers would be the easiest quick fix, but If I end up going with custom control arms in the future I’d ditch the struts and upgrade to coilovers as well. we will see how far I take this project as it totally depends on how much I like “daily wheeling” it.
 
Aftermarket4x4 said:
Motor swap thread dropped on Zuwharrie. I’ll be updating it every few days as I have the time:

2.7 V6 Tracker Build on Zuwharrie.com

…and yes I posed on a rock … it’s actually in my front yard :flipoff2:
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Like it! I’ve got another blown up 16V in my tracker. Badzuki is trying to talk me into the V6 swap. It doesn’t look fun. Would you do it again or would you find something else?
 
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JR4X said:
Like it! I’ve got another blown up 16V in my tracker. Badzuki is trying to talk me into the V6 swap. It doesn’t look fun. Would you do it again or would you find something else?
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I'd definitely do it again .. and again.. and again! I would recommend using a 2.5 out of a 99-05 GV or 2.7 out of 99-03 XL-7 since it matches more of Track/Kick drivetrain.. it just integrates better.

DO IT!
 
JR4X said:
Like it! I’ve got another blown up 16V in my tracker. Badzuki is trying to talk me into the V6 swap. It doesn’t look fun. Would you do it again or would you find something else?
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I think my buddies Tracker has the 2.7 in it. It's been turboed for a long time. Lifted the heads once when the waste gate ****ed up, but a set of head gaskets and studs fixed it right up.
 
Did you need to do anything special for the v6 to run standalone? just pull the harness/ecu from the donor and find a spot to insert the kick sensors for the gauges?
 
Aftermarket4x4 said:
I'd definitely do it again .. and again.. and again! I would recommend using a 2.5 out of a 99-05 GV or 2.7 out of 99-03 XL-7 since it matches more of Track/Kick drivetrain.. it just integrates better.

DO IT!
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I just got an 02 XL7 maybe. Brother says the hydraulic chain tensioner is bad, that’s why he parked it.
 
Looks like there is a fair amount of room behind it, what's keeping it from moving back more?
 
YouTube sucks. I can’t see **** that I want to see in that video. And when you pause it, it covers everything with arrows pause button slide bar.
 
JR4X said:
I just got an 02 XL7 maybe. Brother says the hydraulic chain tensioner is bad, that’s why he parked it.
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Here’s a link to the swap with pics. Updated a few pics yesterday and I’m updating it every couple days with more pics and info.

2.7 V6 SWAP THREAD
 
bdkw1 said:
Looks like there is a fair amount of room behind it, what's keeping it from moving back more?
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The t-case mount is in the original location in case I wanted to install a shifter it would be located properly. The front driveshaft can also bolt right in without being lengthened. Plus the exhaust is very close to the lower section of the firewall. Otherwise if someone wanted to cut a new shifter hole and lengthen the front d-shaft as well as massage the firewall a bit the motor could go back roughly another inch or maybe 2” max.

Here’s a pic I had already taken and it’s hard to see how tight it is where the CAT converter sits very close to the bottom lip of the firewall:

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Cat? You lost me there :lmao:

The ALH in my Samurai! require the heater hoses to be angled. The shifter hole got moved back because AX15 problems. I guess if you're going full ****** and not using anything stock a few minor body adjustments are that big a deal. There is something to be said for using off the shelf parts.
 
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