I'm getting ready to swap a 2.0L into my 92 Tracker.  My current drivetrain is the stock 8v 1.6L motor, stock 5speed tranny, w/ the stock transfer case.  Based on the research I've done, it does appear that the 1st gen t-case will fit on the 2.0L tranny.  Since the 2.0L tranny has a hydraulic clutch, I would have to convert my clutch pedal to hydraulic.
Or, I can bolt the 2.0L engine to my 1.6L tranny with modification of the flywheel and pilot bearing. 

So the question is, will it be easier to swap the engine and modify the flywheel, or swap the engine and tranny and convert to hydraulic clutch?

I'm thinking that if my t-case will fit the 2000 tranny, I should swap the engine and trans.  This will give me a presumably stronger trans w/ a bigger clutch disc.  I can't imagine that it will be too difficult to convert the clutch pedal to hydro, especially once the engine is pulled and I have clear access to the firewall.

Any advice from someone who has done this or a similar swap would be greatly appreciated. Thanks!

Someone on here did this a year or two back and IIRC only had to make up a bronze bush for the centre of the flywheel.

I would like to point out, based on my VSS thread on this very forum  that in your decision process  you should consider how you're going to solve the wireing.

If you're going to keep your existing instrument cluster Your old Tcase will come in handy as you can feed the cluster wirh the mechanical cable and get your VSS input from there.

If you swap in the 2000 cluster, well, you better start thinking of a VSS solution or... make sure you run the 2000 Tcase.

Running 2000 cluster and Tcase is probably the simplest solution. In the long run probably the cheapest, not to mention that evidently it's stronger (tranny, clutch).

The stock transfercase is not entirely stock. It's actually a Kicker 2 with a Toyota case behind it.  So I can either swap in the 2.0L cluster and use the marlin crawler VSS, or I can send my cluster out to trail tough to be modified and use it with the cable from the toyota case.

Someone on here did this a year or two back and IIRC only had to make up a bronze bush for the centre of the flywheel.

That was Aftermarket 4x4.

http://members.cox.net/aftermarket4x4/2litertracker.html

I believe they sell the new engine mounts that are required as well as the brash bushing.  They never did finish the electrical writeup. 

No not Aftermarket4x4, they used a custom or heavily machined flywheel.

I thought Zaggy had done this.

does anyone know exactly what is required for flywheel machining? is it as simple as machining the 2.0L bolt pattern into a 1.6L flywheel? 

The search on this Forum doesn't work very well. I couldn't find the thread by the chap that fitted the bush, Rockrat4x4 were selling a machined flywheel. I think Zaggy had a new flywheel custom made.

Are there kits for the various engine swaps----Seems like after reading as much as I can find----Lots of talk about engine switches but very few actually doing it----I'd like to have enough hp to be able to meet the demands of duning in heavy sand---So would the 2.7 be the better choice-----Tons of built Sammys but so very few Trackers----HOW COME

Happy

does anyone know if the 2.0L bellhousing will bolt onto the 1.6L tranny?  I'm wondering if I can do a bell housing swap and retain the larger 2.0L clutch and flywheel.  Are the tranny input shafts the same?

Tons of built Sammys but so very few Trackers----HOW COME
Happy

The 1.6 into a Sammy is a very simple and cheap swap, there are no simple swaps for a Track/Kick. With the right gearing the 1.6 is adequate for most people anyway.
Aftermarket 4x4 sell a kit for the 2.0 into a Track/Kick.

Power, there's always....... My Way   

Wild