Ok so i've been browsing all the zuk websites and i still have a few questions.  It is my understanding that the high range of the sidekick transfer case is 1.0, whereas the high range of the samurai case is 1.4, or something like that.  I know that there is an adapter available to mate the two cases together for a wide selection of gears, but is it possible to simply replace the sidekick case with the samurai's?  This would yield a lower final drive ratio and compensate for larger tires.  As neat as the dual case setup sounds, im really focusing on my high range driving, but looking at other options besides R & P gears and stuff.  Has anyone done this?  is it possible to swap the transfer case from a samurai into a sidekick, and will it really improve the final drive ratio?

Geared is planning to use a 413 transfer (crawler gears) in the vitara.

using a 413tranny and the 1,6L adapter for the 413 to fit.

with 4,16 (or so) gearing it might be good match with the 33" tyres

I know that there is an adapter available to mate the two cases together for a wide selection of gears, but is it possible to simply replace the sidekick case with the samurai's?

I don't know that simply is the correct word to use. 
Yes, it can be done.  Probably the best way would be to use a 2wd tracker tranny.  Otherwise, when you remove the tracker tcase from the tranny, there won't be any support for the tranny output shaft.  Then frame mounts will have to be made to bolt the samurai tcase to (the samurai tcase is a divorced, where the tracker tcase is a married design).  Then a short shaft that runs from the tracker output shaft to the samurai input shaft will have to be made.

Stock tcase ratios:
tracker high 1:1, low 1.82:1
samurai high 1.409:1, low 2.268:1

So yes, swapping to a samurai tcase will have a noticeable affect on your high range.  If you are running 5.12 diff gears, it will make them feel like 7.22s, if you are running 4.62 diff gears, it will make them feel like 6.52s (if I did the math right).

What gears are you running in your diffs now?  If you don't know, do you have an auto tranny or a manual tranny?

Tony Bennet (aka Red Baron) has done this, there are some pics on the forum somwhere. He posts here from time to time but you can get hold of him through the Surrey Suzuki BBS (he's the Surrey president)
http://www.surreysuzuki.me.uk

Interesting, but sounds like quite the project.  I've got 5.12's right now and im only running 31's, so this may be a bit of overkill.  perhaps with 4.62's and this case it might be just right for  33-35'' tires, but that isnt something thats in the near future for my rig.  thanks for the help.

You might want to take a look at the OTT Kicker 3 http://www.ottindustries.com/kicker3.htm as a solution for running both together.  I'm not sure how you would  make it fit under a Tracker though...

You might want to take a look at the OTT Kicker 3 http://www.ottindustries.com/kicker3.htm as a solution for running both together.  I'm not sure how you would  make it fit under a Tracker though...

 

damn, and that is in a 4 dr!  I was mainly looking at this as a way to save some money over purchasing 5.83's.  I'm not too fond of the dual case setup because i have a 2dr and havent seen that done much.  Has anyone used a sammi case on the track/kick trans either 4wd or 2wd? 

damn, and that is in a 4 dr!  I was mainly looking at this as a way to save some money over purchasing 5.83's.  I'm not too fond of the dual case setup because i have a 2dr and havent seen that done much.  Has anyone used a sammi case on the track/kick trans either 4wd or 2wd? 

I apologize for not stating that all the welding on the sheetmetal inside did NOT have to be done, and that we had a buddy who just started cutting out my floorboards without knowing how far to. I think it really only adds like 6" of overall length.

GRVIT in Greece has a Kicker 3 in a 2 door. Seems to work ok for him.