1990 Tracker SAS using a Samurai axle and leaf springs

[Canadian_Zuk]

Not hardcore by any stretch, but here's my quick and dirty Tracker build, SAS on my bush truck.  My reasons for this mod were simple:

Reduce the number of weak links(moving parts)
Increase ground clearance (without nasty CV angles or flimsy strut extensions)
Make trail repairs easier and faster
Gain some flex
make use of the shed full of spare Sami parts I have

This mod netted me almost 5in of lift in the front.

Parts needed:

Samurai front axle with required tracker gears installed in third (5.13s in my case)
Samurai leaf springs installed SPUA
Shackles (stock or home brew)
Samurai tierod and drag link
Wheel spacers or offset front wheels (I chose wheel spacers)
2 leaf spring hangers for fixed end of leaf spring
2 shackel end leaf spring bushing tubes (I used 5/8" x 3/4" rod ends instead)

Step 1 - hack out all IFS, including crossmember
Step 2 - remove "horn" from frame arch and plate.
Step 3 - box/plate frame where new spring hangers will be welded
Step 4 - slide Sami axle/leaf spring assemble under rig.
Step 5 - bolt up existing Tracker front DS to axle, leaving 1/2" of compression
Step 6 - plumb axle in wheel well
Step 7 - Weld spring hangers to newly boxed setcion of frame
Step 8 - Install front frame side shackle bushing tube.  This step will vary depending on what going on with your front end.  The existing frame rails can simply be extended 2" with some 2x4 box and the bushing tube welded to the bottom.  My bumper was already in place, I used rod ends, only because I had them on hand and didn't have any suitable tubing.
Step 9 - cut and sleeve Samurai drag link to proper length.
Step 10 - Fab mounts and install shocks (I used s10 rear shocks, 9" of travel.  Setup with 4" up travel, 5" down)
Step 11 - add wheel spacers and wheel.    I'm still waiting on the USPS man to bring me my spacers.

Here are the pics.  Sorry, they do not reflect the order of the above steps. 

[95tracker]

that turned out pretty good can we get some action shots...

[Canadian_Zuk]

that turned out pretty good can we get some action shots...

Sure, as soon as I get my wheel spacers on.  I'm rubbing my front shocks at the moment.  I hope they'll be here today.  The whole project took about 16 hours to complete.  Alot of time was wasted cleaning up the Sami axle, regearing, and finding brake parts.  If the Sami axle had been ready to use, it would take about 8 casual hours, or a Saturday.

[Biggerhammer]

How about a few side shots of the rig, showing the entire rig. How did you lift the rear to even it out?

[95tracker]

Sure, as soon as I get my wheel spacers on.  I'm rubbing my front shocks at the moment.  I hope they'll be here today.  The whole project took about 16 hours to complete.  Alot of time was wasted cleaning up the Sami axle, regearing, and finding brake parts.  If the Sami axle had been ready to use, it would take about 8 casual hours, or a Saturday.

Sweet ya i done my SAS before i had my spacers and was eager to do a flex test to see how much flex i gained and it rubbed alot till i got my spacers.

[Canadian_Zuk]

How about a few side shots of the rig, showing the entire rig. How did you lift the rear to even it out?

I just did the rear tonight.  I used Nissan 240sx rear coils, there about 3.5" taller than the Tracker coils and similar spring rate.  I added a 3: extension to the arm that attaches to the top of the diff.

1-grease mounting holes to transfer marks to template
2-place carboard template into grease
3-greas transfers onto templete allowing accurate holes to be drilled (I hate measuring)
4-clamp template to stock and center punch the holes
5-drill both the top and bottom plates at the same time
6-weld em up with the nescessary spacer, them plasma a hole for the ball joint
7-installed on diff
8,9-side shots of the final product.

[Biggerhammer]

That looks pretty good!


Your front bumper looks almost the same as mine...


Mine


Yours



I was thinking of building a small stinger and light gaurds but wasn't sure what it would look like.

[Joe S.]

Looks good!

[Canadian_Zuk]

Looks good!

Thanks.  I just read through your thread, Your 4 door turned out very well.  My wife wants a 4 Door, auto, AC for herself.  I think I'm going to look into the Trail Slayer kit now, looks pretty stright forward.  You did a great job.

[Joe S.]

thank you!

[openoffroad]

hey do you have any pics of how you did the shock mount im doing this same swap .thanks