I've decided to put a 2.0L in the vehicle we are doing the SAS on.  The available 4:1's wont cut it with the 1.6 8V, 5.29's and 37's.

I can't decide what to do with the driveline though.  My first inclination was to go with the Vitara 4sp auto that comes in the vehicle and 4:1 gears  in the tcase.  With the auto, 2.0 and 4:1 I think it would work pretty welll off road and it's nice and clean and simple. 

I'm less concerned with on-road, but I would like it to be fairly decent on the road....

Another intriguing thought though was to use a 2wd 5sp trans and the 2.0 from the Vitara with a sammi tcase behing it.  This opens up tcase to 6.4:1 with the added benefit of high range reduction on the street. 

Offset output isnt an issue for me since I have an offset yota axle already.  I'm worried about the overall lenghth though.....and the durability of the sammi tcase behind 37's and 135HP.

Thoughts & experiences???! 

Isn't there a company that will mate the Sammy Transfercase to the front half of the Tracker case?

the sammy case shouild be fine with 37's AND 5.29's in the diff. The 5.29's make the difference ...

A friend of mine has a 94 4dr with a 4" frame chop, 3" body lift and 35's. He swapped in a full drive train - 2.0, auto trans -I'm not sure what he's using for a t-case, but I'll ask. I haven't seen it in action, but he say's it works very well in mud drags, and that the power difference with the 2.0 is well worth the work. I'll try to get some more details on what he did/how he did it, and what t-case he's using.