Finished the oil passage modification.  I use a write-up by ZuesZuki http://www.zukiworld.com/forum/index.php?topic=21156.0  and added my photos to his good thread.

Finished modified third member w/o lower oil passage.



The samurai housing has a much larger banjo then the aluminum, causing it to hang below the (already lowered) cross member.  So I removed the lower portion of the housing and welded in a patch even with the gear mount (very similar to the aluminum).
Cutting out the bulge

Patch replaced and oil drain moved

I then changed the mount to use third member bolts and original cushioned mount bracket.

And now have it installed


It is setting a little low, the shield on drive flange hits cross member on bumps, so will have to raise mounts 1/2" or so.  I have made some road trips with it, and drove around the field climbing over logs, and testing the ARB.  I am test running w/o the front sway bar hooked up to see how much effect it has on normal road driving.  I know that I am getting a lot more flexing and use of the  ifs w/o it.
I did not get a stub shaft made to use ds CV on both sides.  The ARB that I scored on has 26 spline shafts, and I could not find used ones for less than a new one.  So I had to buy a ps CV to get it on the road.  I am now trying to find a broken 26 spline ps CV, so I can get it modified.  With my present lifts I had to lower everything to get the new CV in place.  I seem to remember that Mike H. had modified his A arm to allow easier CV replacement.  I guess the modifications never stop.
Right now I just want to get some trail time in.

looks good

Just installed a set of OME 956 springs on front. They increased my ride height by 1 1/2 inches over stock 4 door springs with 7/8" spacer.  Tall springs


I am going to do the Hagen widening mod. to allow it to drop a little.  Not going to have much drop left.  May have to either increase the strut spacer or get a set of OME struts.  If I had the gears, there is plenty of room for larger tires.  Oh, I'd need larger tires too.  (How close is Christmas?)

sami dif looks great in there. Good job. The hagan widening mod is pretty sweet, I just finished it (minus a few tweaks to do).

Springs were just too tall, only 1/4" of droop left.  I cut 1 coil off with a 1/16" cut off blade, and ended up with the same ride height.  We put the 4 door springs in my son's DD, which improved his ride.
With the lift I have, I have been concerned about the upper mount on rear end, so I made a new mount for it.
First I cut off the ball joint, then used the eye off an old spring and welded a 3/4" stud bolt to it.  I put two nuts on the stud bolt and positioned it on top of the upper arm and welded the nuts in place. (I spread the nuts apart to make it stronger, as I welded one side of the nut to the upper mount.)   I used a piece of 2" square tubing to raise two side mounts for the spring ends and welded them to the upper diff mounting bracket.  Then I put new poly bushings into the spring and bolted it in place.
This is a comparison of the two mounts.

Side view

And this is with it hanging.

(I ground off some of the front of square tubing for clearance, and put the missing nuts and washers back on.)
I do not have to worry about this breaking, and should have a little better flex.

I got this 2.7L V6 early summer to install in my 93 Tracker, but kept on using the Tracker.  Since NECESSITY IS THE MOTHER OF INVENTION, I sold the Tracker 1.6L 8v and will deliver it tomorrow.  So if I want to 4X I have to get to work on the conversion. 
1st step:  Remove old motor. (done)


Now it looks empty enough.


2nd step:  Size up installation.

It looks a little bigger in the air, then it did settling on the floor.

And YES, it is a little bigger going in too


This exhaust can has to squeeze in there?


I may have to move a few things to get it in, but it should fit.  I know Eric has squeezed at least one in, so it can be done.  I have to get some more parts for this new motor (it was not just rear ended, appears to have had front damage too).  Water pump is shot (now that appears to be a major tear down to replace).  I have some other modifications I want to pursue while the Tracker is OOS, so this build will take some time.  BUT, it is started.

I am going to beef up my diff mounts so they do not break with a little more hp.  (Broke one earlier this summer.)

Just started removing parts that seem to be in the way of my installation.  Removed ps exhaust manifold, so it would drop past the brake pressure splitter.  (That gave me a lot more room, and will figure out how to get it in place once other issues are resolved.) Now it seems that my IFS diff and mounts are preventing it from dropping in place.  Researching past threads I found a link that says that removing the diff makes pulling the motor out a XL7 simple.  So that is the next move.  Diff comes out and motor drops in place to see if I can reinstall the diff, mounts can be modified (again).  I still want to keep the IFS (if possible).

I was wandering what is actually different about the diff mounting. I noticed once at the local salvage yard that the mounting brackets themselves look different, so I wander if they moved (or possibly widened) the mounting location...Maybe they just modified the bracket itself to come off the diff a little lower, to clear the engine. But as you can see from the pictures below the frame mounting holes are relatively different.

For example:
Sidekick mounts



vs. Grand vitara/XL7



I dont know if that changes anything in your case, considering you already had your brackets modified for a drop.....Keep us posted what you figure out.

I was wandering what is actually different about the diff mounting. I noticed once at the local salvage yard that the mounting brackets themselves look different, so I wander if they moved (or possibly widened) the mounting location...Maybe they just modified the bracket itself to come off the diff a little lower, to clear the engine. But as you can see from the pictures below the frame mounting holes are relatively different.

For example:
Sidekick mounts



vs. Grand vitara/XL7



I dont know if that changes anything in your case, considering you already had your brackets modified for a drop.....Keep us posted what you figure out.

Grand Vit frame is wider.  Both sets mount about the same, just a different offset.  My 93 brackets are a little different casting than the top one you show.  If you are lengthing them, be sure to plate your weld area.  A lot of force is on those brackets and if they break, so does a CV.

hey you do some good work. still trying to get your 1.6 in my car. turns out my engine has two more sensors that yours. keep up the good work.

I believe that you can switch the ecm, and included engine wiring to plug and it will work.  Or, just switch the intake setup.  You must have the California model with increased environmental equipment.
I can check the wiring diagrams, but that would not be until end of next week.
I am running into some snags on my swap also.  TIME being the biggest one.

that v6 in mine barley fits they even had to use different exhaust setup on each side.

I have pre-cats on this new motor, and will have about 1/2 clearance, when I get it squeezed in.  Last attempt at setting it in with 1 exhaust manifold off, it looks like I may have a crossmember issue.  Next try is with transmission on so I know where it has to fit. 
Have you figured out what motor is in yours?

I think it is a gm v6 out of an 85 to 87 s-10 or astro van

Finally found some time to work on the Tracker
I removed the motor mounts from the frame, and then moved the brake junction connection from the frame up to the fender well.  I modified the Pitman arm and idler so that I had 1.5 inches of drop (with the motor setting in it steering linkages are almost straight across). I built a brace to go on the bottom of the idler and welded it to the A arm support.


Then I tucked the motor and transmission back in it.  I put a piece of 1" square tubing between the pan and tie rod and set the motor on it.  Still have to center and change exhaust manifolds.


I now have the transfer case mount bolted in place, and I can check and see where the new motor mounts are going to be.

Correction, when I moved the motor to center it, pan was hitting back crossmember.  Tried changing to one of my other Transfer Case mounts, they would not fit.  Tried changing out different TC mount which moved it the wrong way.  Then double checking the XL7 TC mount it is offset about 1/2 inch, and I had it setting with the offset to the back.  Turned it around and pan is now clearing by 1/4" - 1/2".  I may ding that corner in a little (as I slip it back in) to ensure no possible rubbing.
I switched exhaust manifolds to 2003 as my 2005 were bent so they would be hitting crossmember, also pre-cats are a little smaller.  Exhaust on the passenger side is tight, so will probably install a small heat shield (pre-cat already has one on it) just to keep brake and fuel lines protected.
I will be working on motor mounts today.