[dude!]

Hello,

Someone recently reached out enquiring how I did this conversion, and I though I would share the details before it is forgotten. I no longer have the car so I wont have all the measurements sorry.
This project went through 2 stages. The first stage used the Zukparts kit with a new machined spindle bushing as the GV spindle is identical to earlier models except for the spindle bearing id (important later), the second stage was of my own making improving on the idea.

The original zukparts spindle bushing seized two separate times, my guess would be heat/ lack of lubrication due to the lack of paths for grease and lack of grease volume/ debris forced between seal displacing grease. The brief for this project was more grease and improved sealing.

There is a mix of photos from both stages ill try keep up communication if there is confusion.

You will need the following:
2 of: 95GBY-60700808L - DRIVE SHAFT OIL SEAL 56.9X70.2X8X8. its a seal from some sort of toyota.
2 of: 9099970067 hilux cv spindle bushings.
2 of early hilux cvs and manual hubs.
aftermarket control arms for extra room
diff drop bracket for long side of diff.
Some spacers for the hilux locking hubs, I had and used the zukparts supplied ones.

The hilux spindle bushing listed above will need a spacing ring machined and pressed on to match the height of the zukparts supplied one, this is so the locking hub spacing remains constant.
Then the OD machined to press fit into the bore of the Grand Vitara spindle. You must use a Grand vitara spindle as it used a roller bearing instead of a bushing Vitaras did, resulting in a larger bore. They are identical otherwise.





A seal housing will need to be machined, this press fits into the OE seal location and fits the seal listed above which accepts the standard hilux cv seal shoulder.






Then test fit the Hilux CV, remove material from the upright where the CV bell contacts, I used a lathe but a grinder will do the trick. remove as little as possible.



The short side of the diff requires a custom bracket to maximise clearance as the hilux flange is large and the stud shaft will be short. I used counter sunk bolts here for this reason, from memory they were M12x1.5 this is a fine pitch and was hard to find at the time.
The long side was a "standard" 2" drop bracket.





For the second go round I machine an adapter (below) that was welded directly to the vit/GV cv cup, instead of using the zukparts adapters, I cant remember if its possible to get the zukparts adapters to work with an existing stub shaft from memory it was tight for space. Below is the only photo I have for reference, both faces were at their seated height my machined one sitting slightly lower and those few mm where important from memory.



The short side or "stub" side requires a 26 spline Vitara cv cup if using a Vitara locker i.e. stub shaft mod. or GV one if keeping the standard vacuum internals (why would you though) due to the different shaft and spline length.
To maximise available room I cut the cv cup at the groove where the cv boot clip sits and then welded on my machined adapter. I would be fitting the cv and measuring for correct offsets as you want some cv plunge all through its stroke.







The long side of the diff required a spacer and adapter of about 50mm from memory





Had this setup, 32's and an autolocker in the car for a few years after its redesign, and had zero issues. Regretfully sold the car to some one gold coast way hopefully its still going strong.



I no longer own any suzuki's but ill try revisit this post for any queries

cheers,
Zig.