Ive got a 99 tracker that Ive put a 4.3 & 700r4   Im going to aput a samurai ft axle under the ft with leaf springs  But Im running int some small issues  I have the tracker ft 3rd member to put into the samurai axle  but there is some vacuum disconect  inside anyone know if I can
1..   put those gears in a samuraii 4pin carrier and   a steel 3rd member
2..& or  make the vacuum gizmo work
3.. put a regular caririer into the tracker aluminum 3rd in place of the vacuumm stuff

That's the air actuator you are referring too from the Tracker.. It's a pressure line that works with somewhere around 5psi.

You can use manual hubs and permanently lock the air actuator in place using metal straps.. Someone had used plastic Zip Ties and that had worked for him, but i'd prefer something stronger..

Read here..

http://www.zukiworld.com/forum/suzuki-grand-vitara-vitara-chevy-tracker-(gen-2-platform)-1999-2005/damn-i-think-i-really-broke-something-now/

If you have an air compressor, set the regulator to around 5psi only and using a blow tip, pump some air into the diff air line, you will see the actuator moving back and forth as you add / remove pressure. Once you see how it moves, to lock it in place with the ties / straps will be easy..

Or you could use the air pump located inside your front bumper to activate the actuator.. Just have someone shift the vehicle into 4WD with the ignition on..

Good luck with your project and post lots of pics!

Put them on a samurai 4 pin carrier and throw it in a samurai steel third.
The good thing about the 99+ gears is the ring gear is cut differently than the earlier ones and you don't need to use a "can" to hold the crosspins in place.

thanks for the actuator info  I think the best way for me is to use the sami 4pin carrier keep it simple

my plan : 4.3 tbi v-6 700r-4 automatic  samurai transfer case  samurai ft axle with leaf springs (for simplicity)modify the rear suspension to be as high as the ft end . I dont want to build a rock crawler or tuff truck I need a 2 track /snow wheeler that I can use as spare car  so I plan to leave the diffs open . I plan to use parts I have when ever possible to keep this a low budget build
I started with a cheep 4 dr  tracker with a 2.0 auto that I got from the local mail lady I dont think she missed many mail boxes over the years . I swaped in the 4.3 and trans & made a temporary drive shaft & put 50 miles on it to make sure the bugs were worked  out of the ecm & FI no problems there  the first issue I ran into is the speedo was electronic so i had to redo the guage cluster .
I finally got going again I used a samurai steel 3rd & the original tracker R&P and put them into a samurai axle that I had (thats why I chose a samurai axle) and used some cj5 ft leaf springs . I am now to the point where its setting on the leaf springs in ft(not finished welded yet) and sitting on 32 " tires I plan to use 35s now i can see what x members I need to remove for clearance . and where  the steering box will have to go

Ive removed the x member under the engine ,the spring/strut towers . I used a power  steering box off an Izzu pick up and had to notch the frame for the pitman arm to clear  its tight in the engine compartment with the 4.3  but its all fitting pretty good .Ive made some adjustments to the height (a little lower ) now Ive got to add some plating to the frame & weld all spring mounts up.

I got some adjusting done on the ft  and have the rear lifted now here how its sitting as of now

 I got a samurai transfer case mounted and  I got it so the rear drive shaft is a stock length samurai ft  & the ft is the old rear  modified with a samurai slip yoke
got it out of the garage today drove it out back for a bit and the rear bumper rubs when flexing but thats  a easy fix by trimming the bumper bottom  . took it down the road and it drove pretty good   with the 4.3 & a 700r4 & 488s its got some balls

I love it!  Looks great

Looks clean.  Now paint those white rims. 

thanks  guys... Ive got some aluminum rims that Ill put on when I get some 35s  Ive sot some wheel spacers ordered for the ft to even out the track width. I put about 30 miles on it around town and its all working sweet except I wish I had less gear its got4.88to 1 axle ratio.
 here a pic of my transfercase set up and rear  spring/lengthened links