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Old 03-04-2012, 07:11 PM   #21 (permalink)
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Quote:
Originally Posted by fierodough View Post
Remember 2 outer rear bolts in crossmember should be in place before installing as lower control arms block these.
Yep, no way to get that bolt in the hole once the control arm's in place. Torch at the yard took those two out after he cut the bolt that went through the bushing. Never noticed the bolt for the power steering hose... thanks again.
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{{{FRANKENKICK}}} Eng. VIN G16T10XXXX (1996) 1.6L, 16v, MFI, ECU PN:70EA0, SES removed at cluster,
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Old 03-05-2012, 07:57 AM   #22 (permalink)
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Woohoo!

Ok yesterday we went to a local slavage yard (Kenny U-PULL) and payed $16.99 (CDN) for it! (that's about 17.05 USD LOL!) (from a 200X Grand Vitara)

I rewelded the brackets for the steering rack as they did not look strong enough and may have been damaged when the Vitara was in an accident.

Within the next few days I will re-install it in my Tracker and will take pictures and maybe some video as I'm sure I'm not the only one who needs to perform this repair.

Cheers!
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Old 03-08-2012, 07:23 AM   #23 (permalink)
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Sorry for the slow updates guys, the weather is weird here and getting some time to work on he truck is complicated.

Here is part one of a two part video on removing the (rusted) crossmember from the truck.

Tracker / Vitara Crossmember Removal 1 of 2 - YouTube

Part 2 will be up soon!

Cheers!
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Old 03-08-2012, 11:40 AM   #24 (permalink)
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Part 2!

Tracker / Vitara Crossmember Removal Part 2 of 2 - YouTube

I will make the reassembly video as soon as the weather clears up.

Cheers!
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Old 03-08-2012, 08:00 PM   #25 (permalink)
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Nice videos! Thanks.

Well, my crossmember looks at least as bad as yours. I got it out today, but broke both of the bolts that are above the control arm (one on each side). Not only were the exposed portions of the threads rusty, but the shafts of the bolts were rusted fast inside the crossmember. The one on the passenger side was so bad that it ripped a hole in the frame rather than allow the crossmember to slide off from it! So I'm going to need to do some frame repair before I can put the replacement crossmember in. The one on the driver's side let go of the crossmember,, but it's still a headless bolt with about 2" of shaft protruding from the frame. Hopefully I'll be able to work it out of there. All of this was with several days of soaking with penetrating oil while I was prepping and painting the replacement part.

Note to future readers: Inspect the frame rails above and around the crossmember attaching points as it may deter you from taking on this repair. I might not have purchased this vehicle if I had known it would be this bad.

More after the weekend.
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- 1995 Geo Tracker 2dr, Soft Top, 5sp, 4x4 w/manual hubs, A/C, PS, 160,000mi.+ VIN2CNBJ1866S693XXXX
{{{FRANKENKICK}}} Eng. VIN G16T10XXXX (1996) 1.6L, 16v, MFI, ECU PN:70EA0, SES removed at cluster,
4 Firestone Winterforce 205/75-15 tires on stock aluminum rims


- 1999 Chevy Tracker 4 dr, 2.0L, 5 speed, 4x4

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Old 03-08-2012, 08:24 PM   #26 (permalink)
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heat the bolt until it's bright read then rapidly cool it. That should break it loose.

I broke one bolt but it was one of the long ones away from the a-arm. I cut the nut at the top and put in a new nut.

Took the truck for a test drive. My steering is about 5 degrees off but the truck is not pulling. I guess the alignment shop will fix that. Waiting on my lift kit before I get that done.

Cheers!
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Old 05-31-2012, 08:49 AM   #27 (permalink)
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OK, so it's a long time since my last post. Sorry about that, but I was so disgusted with the shape of this Tracker that I put it on the back burner and took care of some other things before coming back to it. Here are some pictures of my front crossmember repair...



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Old 05-31-2012, 08:51 AM   #28 (permalink)
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Old 05-31-2012, 08:52 AM   #29 (permalink)
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Looks pretty sweet NOW!
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Old 05-31-2012, 08:53 AM   #30 (permalink)
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This was a huge PitA for me because I'm getting tired of working on my family's cars all the time. All steel added was new .100" mild steel from a local fab shop and all welding was done with my Miller 110v wire feeder using .030" flux-core wire. If I didn't have so much money freshly invested in this vehicle (just bought it, haven't even driven it yet beside a test drive) I WOULD NOT HAVE ATTEMPTED THIS REPAIR! Now to see if it can be driven long enough to justify the time/money...
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- 1995 Geo Tracker 2dr, Soft Top, 5sp, 4x4 w/manual hubs, A/C, PS, 160,000mi.+ VIN2CNBJ1866S693XXXX
{{{FRANKENKICK}}} Eng. VIN G16T10XXXX (1996) 1.6L, 16v, MFI, ECU PN:70EA0, SES removed at cluster,
4 Firestone Winterforce 205/75-15 tires on stock aluminum rims


- 1999 Chevy Tracker 4 dr, 2.0L, 5 speed, 4x4

***Please disregard the 'Expert' label as it appears under my user name. Thank you.***
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