will the third members from a track/kick fit on a sammi :-/
I know RRO sells some kind of kit for using them but I thought you could only use the rear. I would like to use the 5.12's on my brothers because he's got 35's  we'll find out tommorrow just how slow the stock gears are going to be. We put in a 1.6 thanks to freebird so were going to be making good power but I'm pretty sure were still going to need gears.

It's the front R&P that fits in a Sammi third member. You can install the whole front third into the rear of a Sammi but it will have an aluminum carrier. That is not the best way to go. The best way is to install the ring and pinion gears in the steel Sammi carrier.

It's the front R&P that fits in a Sammi third member. You can install the whole front third into the rear of a Sammi but it will have an aluminum carrier. That is not the best way to go. The best way is to install the ring and pinion gears in the steel Sammi carrier.

i thought you put a tracker front in a sammy front?

stu

i thought you put a tracker front in a sammy front?

stu

oops!!!!! Read below

Here is some light reading for you. This info was written by Michael Whitfield. He is da man when it comes to kick gears

The facts about swapping Kick gears into a Sammy axle

Generally:   Kick gear is
Auto 4wd 4.62:1
Manual 5.13:1.
All sport models are 5.13:1
4dr. auto's With OD come with 5.13's

To do both Sammy Front & Rear you will need two Track / Kick fronts + the install kits (about $75 each and include ring gear spacer, center pin can, crush sleve, New pinion seal, New nut, New washer).

*** Also covers setting them up on the CHEAP   for those with NO extra Cash***

I have set 2 of them up sucessfully for FREE with out the install kit but I wouldn't recommend it.

Yes Tracker Kick front 3rd's will drop right in a Sammy front housing BUT they will be weak unless you use the Sammy 4-pin carrier.

Installing Track /Kick front in a Sammy Front Axle (using the Aluminium Tracker carrier):

Harvest ring gear and carrier from donor Track/kick front carrier.

Harvest ring  gear and carrier from Samurai front carrier.

Clean parts very good with solvent...  Dry and check parts over for wear or damage.

Install sammy 4pin carrier into Tracker 3rd.

**** Must use the Can or tack weld the 4-pins as the Kick ring gear will not hold them securely on the sammy 4-pin carrier.

**** Must use the Ring gear spacer on the Sammy carrier OR you will be required max the carrier ring gear back lash adjustment to one side creating unequal axle spline engagement right to left (In the side gear).  

**** Kick and tracker thirds can be set up this way on the cheap (free).  And Justin my Gunie pig hasn't broken them yet.  

Installing the Tracker / Kick ring & pinion in the Sammy steel carriers:

Compare Pinion gear heights (Inner penion bearing race to end of pinion gear) and Crush sleeve heights.

Ideally you are trying to use this measurment later to assist you in setting the proper pinion depth (shimming the pinion).   Usually this Pinion depth measurement is scribed on the back of the pinion gear and is a measurement from the carrier housing face to the finished gear end of the pinion shaft.  You will adjust this measurement by installing or removing shims between the Inner pinion bearing and the carrier housing.  Install your pinion shaft, shims, (always try stock sammy ones first), and the inner and outer bearing (no crush sleeve) along with the old pinion washer & nut.  just tighten snug as to take pinion depth measurements.  Once the measurements are correct you can beginto set up / test fit the carrier.  

The Track/kick ring gear is larger then the sammy ring gear and there for requires a method to hold the 4 cross pins that the spider gear run on (4-pin) in their place in the carrier.  I believe most venders are offering a thin steel "can" that is tack welded into place.   I have in the past tack welded the cross pins, thus avoiding purchasing the can.  My tack weld method is cheap and therefore debatable, I have yet to have one fail but the risk is yours if you try it,  Their is the possiability of the tack weld failing and the pin coming loose thus the can is cheap insurance.  Next install the ring gear spacer onto the carrier along with the ring gear (make sure the bolt holes for the ring gear and threads in the carrier) are absolutly clean).  The spacer is necessary due to the smaller pinion gear and the ring gear's need to be located closer toward the center of the carrier.  Insall the ring gear bolts with red loc tite, and thread them all hand tight, next tighten them (with a torque wrench) in a cris cross pattern in 2 or 3 step to their final torque.  It is very important that the ring gear is pulled down evenly and the that the bolt load is equally placed.  Next Oil/ grease the Carrier bearing's outer races (to help it slide while adjusting back lash) and  place (drop) the carrier into the housing gently meshing the ring & pinion gears.  Install your carrier bearing caps about hand tight.  You might go an additional 1/2 turn but you will still need to have them loose enough to move the carrier assy side to side so that you can properly adjust the ring gear back lash (Free play).  Now Carefully thread in your carrier adjusting rings (round threaded pieces with all the little holes in them).  Screw these until they are snug against the carrier bearings, While checking the back lash (the free play between the ring and pinion).  You should maintain back lash while snuggin the adjuster rings against the carrier bearing outer races.  Now measure your back lash.  Use your carrier adjustment rings to move the carrier & ring gear assy right or left for more or less tooth enguagement.  More toothe engagement  (Bringing the ring gear closer give less back lash).  Once your back lash measurement is correctly set, you can begine to look at your gear tooth contact pattern.   Here is where you can use the Tooth guide at Randy's ring and penion to assist you in visually inspecting the Gear tooth contact pattern to determine necessary changes to the pinion depth.  Once you achieve the correct pattern, (Correct pinion depth & back lash) you can remove the pinion for the last time.  Here once you are sure you have the pinion shimmed correctly you can install you new bearings crush sleeve, seal, washer, (Loctite) and nut... Now tighten the pinion nut to set the pinion torque.  The last rear I set up (Wifes ZJ) required a free rotating torque (force) of 12 inch pounds.  This required me to tighten the pinion and crush sleve until it took 12 inch pounds to turn the pinion nut with no ring gear.  Once this is accomplished you can drop in the carrier/ ring gear assy.  Take care to again accurately set the ring gear back lash.  Once this is complete you can torque the carrier bearing caps.  Again torque these bolts in steps leading to their final torque value (here loctite is debatable).  Once complete re-check you gear tooth contact pattern and your ring gear back lash.  Once these are verified correct you can install the carrier into the axle.  

Rear Axle

Kick Tracker Front gears in a Sammy Rear axle set up follows the same assembly proceedures as the front but uses the Samurai Rear axle side gear (Installs with the Sammy rear 4-pin carrier)

Sammy side gears (Front and rear) should be checked and or replaced.  I see frequent failure in Side gears & related parts from bent axle housings.  Most often signs of a bent using are failure of splines on the inside of the side gear (Ones that engage the axle shaft), and sharp side gear teeth.

          Feel free to correct / edit / debate


All above information came off of the top of my head while at work....  

Specs needed:
Ring gear bolt torque ?
Carrier bearing cap Torque ?
Pinion back lash ?
Average Pinion depth measurement?        
Pinion bearing Preload  (10 inch lbs if I remember correctly)

The tracker front splines have the same count as a Sammi rear

That depends on the year. 95 and older are 22 spline like the sami front.

Mike

ok, read most of it.

stu

wow thats quite a response I'll have read it more carefully when I have a few minutes maybe tommorow thanks I was considering this out of a cost issue I don't feel like forking over $400+ dollars for new ring and pinoin sets for a sammi and the local bone yard wants $80 for tracker third members :-/

 Yet another point about the swap. You can use the kick rear diff using what is called a hybrid rear. You can buy one from Trailtough, Petroworks, and Sky mfg. They take a kick rear housing and a stock(not spoa) sammy housing and make one out of the two. It works out rather slick. It's been there, done that for me. It's a really nice setup. The average price for the hybrid is around $150 plus cores, where applicable. You can have Brent setup the kick front gears in a sammy dropout for like $100-$150. I know that will help.