I was contemplating this some time ago. Supposedly, a 2wd tracker transmission is the easiest to work with a Samurai case. Yes, I assume there's much more to it than that, and you'd still have to figure out how to make an intermediate shaft, but I would also think a 2wd trans would be shorter than a 4x4 trans, helping with driveline angles and other issues.
I don't know exactly what I'm talking about, but I try to help point people in the right direction to good advice.
This is the advice I was given on the second page here:
http://www.zukiworld.com/forum/general-suzuki-forum/transfer-case-swap-gears/How about the OTT Kicker setups? The Kicker 1 says it adapts a Samurai case to work in the Samurai with a Sidekick engine and trans swap. So could this theory be used to adapt a Samurai case into a Tracker?
And the Kicker 3: does this adapt a samurai case to run behind a Track/kick case? What about the rear driveshaft length? I'm running a 2dr.
I would say a kicker 3 would be your best bet, between the two. Since the kicker 1 is made to run the samurai tcase in divorced mode....which will make the drivetrain that much longer (something you can't really afford, in a 2 door trackick).
The kicker 3 shortens up the overall length of the trackick tcase and couples the samurai tcase directly onto the back of the trackick tcase. It is still going to be longer than the original trackick tcase by itself setup, but not as long as a kicker 1 setup. You are still going to have the issue of a shorter rear driveshaft, and I am not sure how much you can shorten the 2 door trackick rear driveshaft, before it becomes a problem with ujoint angles and such.
One other thing that guys do, that don't need the extra gear reduction in low (which is provided by keeping the trackick tcase), is to run a 2wd trackick tranny with a divorced samurai tcase. I am not real familiar with that setup in a trackick, so I am not sure how that affects rear driveshaft length. There is also the option of just removing the trackick tcase from the trackick tranny and running the samurai tcase with an intermediate shaft (that makes the overall drivetrain shorter than running the 2wd tranny with a samurai tcase). Again, I am not real familiar with that setup either, so someone else will have to give you more info on that.
One other thing to keep in mind, is that a samurai tcase has an offset rear output, so you are going to have complex ujoint angles on your rear driveshaft. Many people run that type of setup in a samurai (when they run a trackick rear axle) without issues....but just something else to think about. So that being said, the longer your rear driveshaft can be, the better.