Thank you so much for the link and the video. They helped immensely. I just pulled the left side off when I began trying to figure out what was wrong. It appears that I am missing the "smaller" spring that holds the follower to the clutch gear. Thus the clutch will engage but will not pull back away from the engaged position.

Now to find the needed parts. Again, thanks for your prompt response!!!

Mike

 

Are you sure that the clutch spring is not curled up inside of the follower itself?? Not only is the spring important, but you need to get the exact duplicate, if you don't have it, as the tension, etc., on that spring is important for holding the clutch in level. If you have the original hubs on your car (Aisin) you will also be able to find that spring (just the spring, the clutch is a bit different) on any Toyota 4wd truck from around the same years (1988-1998) as they used the Aisin hubs also. Hopefully your local junkyard will have it, or else will have the locking hubs from a wrecked Trackick, etc.

 

Thanks again Bex... I will dis-assemble the unit again and see if the spring is curled tight in the follower.... Actually don't recall looking that close. Now I know what I am looking for.

Mike

 

I did it!!! Found the smaller spring curled up inside the follower. With a little tenacity I got it back together. Cleaned and lightly greased both sides. Tracker runs like brand new. I have had it for 23,000 miles and have always noticed a vibration at 60-65 mph. Thought I had bad u-joints. I now surmise it was the constant turning of the additional mass in the front end. Quite a bit smoother now as well as quieter.
Thanks Bex for your input and assistance. The pictures and video helped a bunch!!!

Mike

 

You're welcome. I am quite familiar with that little spring, as mine was stretched out just the smallest amount, and so was completely unusable, along with some other problems. Got some replacement parts from one of the posters here, and others from a Toyota Hilux.
Glad you got it sorted. Don't forget to service your hubs once yearsly. Download the Manual Hub Clutch assembly info from the above link, as by this time next year you will have completely forgotten how to do it!!

 

Hello all,
Just read this post as I Just bought OEM AISIN front hubs from Lowrange 4wd. I read this:
"If you purchase the OEM Aisin manual hubs from a junkyard or second party, make sure to get the cone washers/bushings."
I have a question for Ranger88den: If I bought these hubs brand new from lowrange 4wd do I still need these cone washers/bushings? I am converting from stock auto hubs to OEM Aisin manual hubs which cost 90 dollars each! I will be installing these this weekend. Thanks

 

You can, but I wouldn't. You may get noise and probably premature wear. I would continue to use the autos until you locate the cone washers. Try Low Range, Trail Tough, ebay, maybe Khodabear or another seller in the classified section. Good luck

 

ranger88den,
Ok, so I bought these brand new thinking everything i need is in the box. In the box is the brand new hub pre-assembled with bolts ready to install. So I am not sure what the cone washers/bushings are. I checked mySidekick FSM and cannot find a picture or mention of these. Do you have any kind of picture of what these look like? Where do they get installed? I would appreciate any help here and thank you ahead for any info.
Thanks,
Mike

 

I would think that if you were buying these from Lowrange, they would be providing the cone washers for you. Often, when junkyards or private parties remove Aisins from an existing car, they wreck the cone washers in an attempt to get them off. If you look at the bottom diagram, #8 is the cone washer, shown at the bottom of the diagram where the hub locker is:

 

Thanks BEX!!!
I see what you are talking about. The bushings inside the hole on the hub...ah...I see. I just emailed low range...we'll see. They should be able to get them...we'll see what they can do for me.

 

These are off a Samurai, but the same as a Track/Kick.

 

Ok Guys.
I see what you are talking about. I emailed LowRange, they sell all sorts of kits. They are directing me to buy the stud kit that fits 1979-1985 toyota front straight axle. These will fit, right? Also, will these studs "clear" the stock rims so that I can re-use the Plastic Hollow Cone that goes around the Hub and attaches behind the Rim?
Here is a link:
Toyota Knuckle Stud Service Parts
They are expensive...but they will work right?
Thanks everyone

 

Looks like $36 just for 12 cone washers, and who knows if they'll fit correctly + shipping? I think I'd wait/look for OEMs. Maybe Bex can get you a Suzuki part # and you can do some price comparison.

 

Did you check the old auto hubs to see if they have cone washers, if they are original they should.

 

Auto hubs do not use cone washers.

 

Again ,
thanks guys. Bex: would you have a part # for the one washer and the bolt (number #7 & #8) in your Picture that you attached earlier? Then I can search for it? Tomorrow I will take a look and see...maybe the auto has cone washers...i'll take a look and let everyone know. we'll see saturday...
Mike

 

#7 is called 'bolt' and the p/n is 01570-08253
#8 is called 'washer' and the p/n is 43841-80001
Here, at SW Suzuki, using the washer p/n
Suzuki Parts - Suzuki Parts | OEM Suzuki Parts | Genuine Suzuki Parts.
Cost is $3.38 online.

 

Mike, I think you owe Bex some rep. points.

 

Cute. I thought I'd at least get a beer out of it.....

 

Bex,
Thanks for the info! Southwest suzuki is much cheaper than here in california (Santa Ana, CA). I am almost ready to order...I have the order on the screen and I am ready to go...I will wait till tomorrow. I want to take one last look at at my current Auto Hubs and check the bolts, etc. I am going to pull one bolt off and take a look. You are sure about these part numbers, right? Total price including shipping is 69.69. Thanks BEX!
Mike

 

Those are the p/n's for the cone washers and bolts listed in the parts catalog for the stock Aisin manual hubs. You can confirm it on the Suzuki website by inserting the p/n - or confirm it by email to Keith at SW Suzuki, if you wish to make sure before you order.

 

Thanks BEX! I will confirm before I order...thanks agin.
Mike

 

You're welcome. Hope it works out for you.

 

Geo Tracker Manual Lockout Hub Bolts | eBay

 

Perfect timing, Ranger!

 

I hope Mike has a PayPal account + the seller has 100% posi feedback.