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My Sidekick project with Trail Tough solid axle swap!

92K views 128 replies 38 participants last post by  dkubek  
#1 · (Edited)
Hi! My name is Aaron, I haven't posted here in a looooong time because I got side tracked from my original off-road project truck...


...and started a company (driftmotion.com) doing 1jz swaps in these...



...but decided I want to go rock crawling so I just bought this...
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In the past I would have built it up over time and made a huge 2 year long project out of it, but we're so busy with project cars and our website that I wanted to get something I can just bolt on and go have fun. I know that the mods are not going to stop with this kit I will be installing, but at least I can get the major part of it done and upgrade other things in time.

I decided I am going to turbocharge my little 1.6L, so stay tuned for that!!!

I placed an order with Trail Tough on Monday, I can't wait to get everything!!!

Here's what I have ordered from Trail Tough so far:

Front and rear Toyota axles with new 5.71 gears and Lockrite lockers installed

Trail Tough Straight Axle Coil Spring Conversion Kit
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A late model Sidekick transfer case with Trail Tough Rockmonster 4.24:1 Transfer Case Gears installed
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Trail Tough Nerf Bars

Trail Tough Front Bumper
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Trail Tough Rear Bumper
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#13 ·
personally i would not go higher numerically than 5.29s. you will love the lower geared tcase and will be fine gearing wise with the 5.29s. friend of mine has a 4door with toyota front and rear axles and 5.29s and 4.24 tcase gears and it crawls great!
 
#14 · (Edited)
I have the 5.71's and they are fine so far. Same with the ARB lockers. Everyone told me that they would fail. They have not yet, and I have 10k miles on them already. The shop that built the 3rd members told me that they would not guarantee them. I said fine, just set them up right. I'm only running 33's though.

Oh yeah the trail slayer kit works great. You should be very pleased.
 
#15 ·
Ok, thanks for all the tips on the 5.71 axles, point taken and promptly dismissed. :flipoff2: Let's get past the gears now please! LOL


Look! If you post pics of stuff on the forum, the next day it shows up at your house! :eek: Sweet! I'm gonna post lots more pics! :grinpimp:
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#43 · (Edited)
Out of curiosity, anyone run the Marfield UM-05? At $80, they're very tempting. I'm in a 4-door SAS on yota, 4.88 Yukon (soon to get Aussie Lockers) with 35" tires. Was thinking of getting a pair, but there's no real data comparing these birfs that I can find... and at $650 a pair, I have to wonder if Longfields are over-kill on a Suzuki?
 
#20 · (Edited)
Made some great progress on the engine today! The engine only had 600 miles on a fresh rebuild done by the previous owner, but all the old peripheral items were bolted back on the new engine. I noticed when I test drove it that it felt a little sluggish, it sounded fine but it seemed to hesitate on acceleration and didn't want to rev in the high rpm. He told me when I picked it up that he was on his 3rd battery, and the guys at AutoZone had checked the alternator and said it was charging the battery so they couldn't figure out what was wrong. Of course it was charging, :eek:THE ALTERNATOR OUTPUT VOLTAGE WAS 17.8 VOLTS:eek: I can't believe they didn't see that the voltage was that far off! It was making the battery leak and loading down the engine so badly that it didn't want to rev. I bet it was using 10hp just to turn the alternator. I got a new alternator and threw it in tonight, and it runs soooo much better. It felt like I was towing a trailer before, compared to now.

New alternator:
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Fixed battery mount that was not even functional before. You can see all the rust that has built up from leaking batteries, I really need to fix that soon.
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I went to the junkyard today with my buddy and we looked for a Sidekick to grab some power steering components and an AC compressor, but no luck. :( Not even one to be found at the junk yard.

I have a long way to go with this engine bay, but it will get there in time... It's nice to be starting with a fresh long block though, everything else is an easy fix.
 
#24 ·
I went to the junkyard today with my buddy and we looked for a Sidekick to grab some power steering components and an AC compressor, but no luck. :( Not even one to be found at the junk yard.

.
I have a track/kick ps a/c setup I will sell. $300 you pay shipping
 
#21 ·
In the past I would have built it up over time and made a huge 2 year long project out of it, but we're so busy with project cars and our website that I wanted to get something I can just bolt on and go have fun.
X2...this is exactly where I am at. Stoked to see another Kick project. The TT kit has turned these into an abundant source of cheap streetable but capable platforms.

Looking forward to seeing how the 35s and 5.71s go down the road...my next rig while be a part time dd. Trailering sucks...btdt.
 
#25 · (Edited)
After researching the power steering conversion, I found that the stock Sidekick power steering is about the weakest setup of any 4x4 on the road. I think I am going to go with a Toyota setup instead. I have several 7M Supra pumps laying around and plenty of different reservoirs, plus we already make custom braided stainless ps lines, so that should work better.

I'm not sure if the Sidekick ps box would work ok with a better pump? I see conversion kits for Sami's to use a Toyota IFS box, do they have that for a Sidekick?
 
#26 · (Edited)
It's not done yet?!

Sidekick came with a 1.3 in 89. You will never see any different in the states.

I got every "Bolt-on" you can put on the 8v under $200. I would say I'm up 15%, but they got more torque than 16v's.

I am gonna be building another 1.6 from a 93. Gonna bore .40 over and put the head off my dad's 1.3 (Trail Tough built it for 1.6 8v valve's) on it. Hoping to get 90-95hp out of it when I'm done.
 
#27 · (Edited)
I had a chance to do a little wheeling in the Sidekick in stock form last weekend. It's a really capable little vehicle other then ground clearance! I got high centered on a rock by accident trying to back up, and spent about 30 minutes getting unstuck with the stock jack and some helpful local rocks. :laughing: And I got lucky at the junkyard, I found a Sidekick with PS and AC to swap onto mine!

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#28 · (Edited)
Tonight was power steering and AC install night. Unfortunately I was only able to get the ps working though. I ran into a few unexpected things with the install.

The steering shaft was longer on the old manual steering box, and I forgot to get the shaft off the parts car today! OOPS
I was not going to be hung up by a minor setback like that, and I didn't want to drive for 30 minutes at 7am to the pick-a-part again like I did this morning. I cut 1.5" out of the manual shaft at one end (the collapsible feature will still work the way I did it), and welded it back together. It worked out perfect, and it seems like the old steering shaft is a little stronger then the newer one, so I was happy to be able to save some money and time by doing that.

Oh man I love the power steering! It is so much more enjoyable to drive now, and it centers really nice. I'm so glad I did it!
This was taken part way into the install:
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I also found that the fitting between the upper AC hose and the aluminum hardpipe is different then the hose from the newer parts car. :shaking:
So I guess its back to the junk yard again after all :(


Look what else showed up today! Thanks to all those who were busting my balls about the Longfields! They look so pretty I'm not sure if I should set them on my shelf like a trophy or install them in my truck. :D
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#30 ·
Tonight was power steering and AC install night.
Look what else showed up today! Thanks to all those who were busting my balls about the Longfields! They look so pretty I'm not sure if I should set them on my shelf like a trophy or install them in my truck. :D
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Well, since they are ONLY 27spline, I'd say set them on your shelf.:flipoff2:

Seriously, they are fine. ****, the Marlins would have been fine. But if you ever twist off the inner shaft, remember the name Yankee Tim.:grinpimp: JK

You could always post a paypal addy and start a fund for your 30spline inners. I'll start it with a donation of $2.50. Find 39 others and your set!
 
#33 ·
Thats a good deal on the rubber. You plan on roading this or strickly off-road? Reason? I recently moved to Pit Bull Rockers and I can not stop speaking high enough about these sneakers. Absolute monsters in the rocks. However, they are bias, which is better offroad, but supposed to be less perfect on. I, however, found them good on the road as well.

BTW - get 5 tires, you know, in case one goes flat.