[GRANDBAZOOKA]

I have the first of the 1998 grand vitara 2.5 v6 manual,it has started clunking whilst under load in 4x4 low,it doesn't appear to jump out of 4x4 low but makes a hell of a clang! I have replaced the front diff with a steel one and recently replaced both drive shafts. I drained the front diff oil and there is no visible metal in the used oil. It is starting to piss me off as i cant plant my right foot when playing in the bush. Any help,advice would be very much appreciated

[SierraDan]

Are uni's okay?

[GRANDBAZOOKA]

Yeah,as far as i can tell they are all good. No tight spots that i can feel,or any play.

[SSSIERA]

i know this might be a stupid question but are your front and rear tyres the same size

[TheRealCJ]

Another stupid question, but have you checked that your front drive shaft is unbent?

[GRANDBAZOOKA]

It cant be the drive shaft's because i only just replaced the both of them,and was doing it before hand and still clunking now. I am over it! Would it possibly be the transfer case???

[royce]

did you put your gears back into the steal diff?

[fordem]

Does it clang in 4HI also? If yes, does it jump back to 2HI?

There are two different problems that can cause a clang in 4WD on the 98GV, one is a front diff issue and the other is a t/case issue - if it's the diff it will clang in 4HI and stay in 4HI but if it's the t/case, it will clang and jump from 4HI to 2HI.

Steky is the man to talk to - I believe he has a thread with the part numbers to fix both problems.

[GRANDBAZOOKA]

I swapped the complete steel diff over,genuine gears and all.
On occasions under load it has jumped out of 4HI too. I use to have a 2000 model 2.5 v6 GV and never had any trouble with this.

[royce]

GRANDBAZOOKA wrote:

I swapped the complete steel diff over,genuine gears and all.
On occasions under load it has jumped out of 4HI too. I use to have a 2000 model 2.5 v6 GV and never had any trouble with this.

Are the ratios the same? I thought all steel diffs were 4.3

[GRANDBAZOOKA]

The diff i took out was steel too though?

[royce]

you had the bang before you changed the diff?

[GRANDBAZOOKA]

Yeah,its progressed to get worse though.

[carlos83]

This sounds exactly like the problem I've had and others with early GVs. Does yours jump out of 4wd H?

I'd gues that its the transfer case.

I had the two problems in high range and low range start simultaneously.

Hopefully a new transfer case or the new gearing in it will fix your problem.

http://www.auszookers.com/index.php?nam ... ic&t=21784
http://auszookers.com/index.php?name=Fo ... high+range