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02 carry LSD kit install

Discussion in 'Suzuki Carry' started by SDK1968, Mar 16, 2023.

  1. SDK1968

    SDK1968 Active Member

    im always too wordy, will keep this to the basics. the directions give you all you need to know & there are 2 youtube vids that i'll link as well.

    the take apart:
    this was a little more external work than i thought.
    get her on some jack stands
    drop the back wheels
    pull the drums. (trick coming later)
    some people take all the brakes off in their vids... i did not have to do that. DID have to unhook the brake lines to have enough play to get the axles/backplate to disengage.
    time for that trick! so to get the axle out a fella turned the drum around backwards, lugnutted it back on & then used that to give it a couple good wacks with a 2lb hammer. shaft popped right out! didnt have to pry on the backplate or beat the axle to death. nice trick!

    at this point i dropped the drive shaft, opened the cover & took the unit out. it was in good shape, no shavings or gunk. took it apart, took the ring gear off. you might not have to do this, but i marked each side & orientation so that they went back exactly the same. got it all apart & then it was time for the "machine work".
     
  2. SDK1968

    SDK1968 Active Member

    about that machine work:

    chucked these up in my mini lathe. pssh. man that would have taken forever.
    moved over to my bridgeport= DAMN!! these gears are hard. after about 20 mins of making micro passes gave up on that.
    went over to the belt sander with the blue rough belt. YES this is the way to do this. much much faster. still spent about 60 minutes on each big gear getting them down evenly, test fit, take more, lather rinse repeat. eventually i had enough room to slide the unit in there. im not gonna throw a hard number at how much i took off of these cause your gears may be different.... i will say that it was enough that when you look at the inside splined section? almost all of the bevel was gone.
    the directions say to have 3 to 6K's of clearance on install, so 5k is what i went with. then it was time for final assembly.

    just follow the directions, they are really good. (will attach a copy here) after that? put it all back together, filled the rear diff, put the brakes back together, ran new brake lines since mine were patched & junky. bleed the brakes & go test it out!
     
  3. SDK1968

    SDK1968 Active Member

    so testing it out= no wheel barking on my concrete, it still has slip like its supposed to, BUT now if you dump the clutch it will bark on both sides.
    If you do a hard start in the yard? you do get rooster tails on both sides. went down over a fairly dry hill that ive never been able to get up before in 2wd.... Yup. rooster tailed my way right up it & over it.

    is this as good as 4wd? oh hell no. did it make a huge improvement from my 2wd open diff? YES. i think this is well worth the $350.

    now about those links & directions:

    the parts: https://www.tractionconcepts.com/Suzuki-Carry-Every-RWD-AWD-5-spd-LSD-Kit-p/tcxsz3343.htm

    tips & tricks:



    the directions:
    this video is NOT the type of rear diff in this truck but the work after that is all the same & a pic of the directions is below.


    https://www.youtube.com/channel/UC3T6ajh2IFAArIZftN8U4Zw/videos
    all kinds of vids so you can get the general idea TC Instructions Inside .jpg
     
  4. Wickedawesome

    Wickedawesome New Member

    Awesome stuff, it seems the forums didn't have too many people documenting Traction Concepts installs.

    How's the performance now?
    Is the dry road cornering still as original?
     
  5. SDK1968

    SDK1968 Active Member

    the "grab" is still getting better as it goes & the guys out there at TC said it would take a good bit for it to get its break in done.

    there is absolutely no chirp or feel at all from it on any surface making a turn. they advertised it that way, but it really is.

    the "dirt" performance is pretty good. what ive noticed right off is it seems to grab quicker when your harder on the throttle or demand in a bind.

    the guys out at TC also said that if it doesnt grab to my satisfaction after the break in that they will get me astronger set of springs/shims to make it grab as hard as i want it to.
     
  6. SDK1968

    SDK1968 Active Member

    a little follow up on this & the front end repair....

    both are working fine & got to put it thru its paces on some steep climbs with load yesterday. the front end is working just like it did before, but now it stays in 4wd. the rear end seems to grab better with each outing. you can literally feel it when it grabs & spins both wheels instead of the 1 wheel wonder.

    verdict===== money well spent.
     
  7. fmartin_gila

    fmartin_gila Well-Known Member

    Kudos to you. Sounds like you are finally getting to the point of having a perfect vehicle specially tailored for what you need it to be.

    Fred
     
  8. SDK1968

    SDK1968 Active Member

    Fred,

    You are too kind.

    You are correct that this is perfectly functional for the hard use it gets here on the mini-farm.

    perfect for "me" though? well my dream mini ? oh that would be a brand new mini with a dump bed, AT, A/C, pw, ps, cc & remote start. :)
     

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