How is yours running?  Have you got the new dash in yet?

It's running great.  Every time I push the pedal I smile.  I have other issues to work out.  (I put the XL-7 coil springs in it for lift but they hit the calipers  - no brakes! - so I opened up the back stops and now have poor turning radius.  Plus I realized that I do mainly city pavement driving  and the spool in the rear is making the rearend worse for wear.  It's making rumbling noises when turning short in a parking lot.)  I haven't finished the dash yet . I think I might go carbon fiber hood.  I guess I have only minor experience with fiberglass so it is a bit daunting.   I tried to make an aluminum one, but that ended in ugliness.  I'll post pics as soon as I get it done.

Best of luck sorting out those gremlins.  It sure takes mega-patience to do this kind of swap plus have issues in the end...I don't want to even think of what I'd have done...

P.S. Have you figured out how many hours you've got into it?

P.S. Have you figured out how many hours you've got into it?

Hours?  Do not mention hours to my wife...  I have more hours on the manual, than on the build, and almost as many hours trying to find parts as on the build.  Setting motor, transmission, & transfer case was the easy part.  I scored on another engine w/small knock in bottom that had emissions electronics on it to replace my broken ones.  It was a BIG score, because my motor came out of a rear-ended vehicle (that had been sandwiched) and cooling manifold under intake was broken, the front cover on mine cracked when tightening after replacing water pump, catalytic converters were smaller, ETC.
Making wiring and connections really ate up time, and presented biggest gremlins.
I have came to the conclusion that the 1601 DTC communications failure from not having a BCM is putting the ECM in FAIL SAFE MODE, causing the TCM to do same thing resulting in only having 3rd and 4th gears and no lockup.  As I said, it is not a rocket on take-off, but no slower than the old tracker was, so I can imagine what yours must be like with a first and second range working.
Now to find a BCM, with connectors/plugs.  I ended up making one of the connectors for TCM, and the BCM has more connectors.

I am using Tracker radiator with electric fan, engine temp likes to run at 205 (when idling), but book says thermostat is full open then, so not worrying yet.  What is your temps running at?

  What is your temps running at?

I'm actually not sure.  I've got the e-fans to kick on at 185, but they hardly ever run.  Unless its hot out and I'm idling in traffic.  Or if I've been using the skinny pedal a bunch, they might kick on for a few seconds at a stop.  I've only got the stock XL-7 gauge (so no numbers) that doesn't go above the middle of the gauge.  Sorry I can't help more.  I suppose if I picked up an OBDII reader it might tell me...

The Tracker is now running without any codes!!!  Just finished rewiring it with connectors for most of the wiring.  I had two crossed wires (GRN/RED & GRN/ORN) and a couple of the power wires coming from wrong source.  Once power was right I lost the 1601 communications failure Code, then I followed the FSM to diagnose the open wire (except it went to another pin) and fix it.  It rolls right out, and may be hard to not enjoy the  power and sound too much.
Still have to clean up wiring job, fasten everything down, fix hood, then paint and trim it out.
But it is now running.
Thanks Muskegtracker for the information you have provided.

I know you guys have been neck deep in other projects up there, but just curious as to the status of your build? Rteally been enjoying following this.

I know you guys have been neck deep in other projects up there, but just curious as to the status of your build? Rteally been enjoying following this.

It now runs and transmission is shifting.  Still has a few issues and one code 2227 that I had used a resistor to fool computer.  It is for barometric pressure, and weather keeps changing throwing my resistor out of calibration.  With last set of parts that I got, I got the vapor vacuum canister (a huge contraption that goes under car) that has the barometric pressure sender, but because of the size I am still trying to get around it.  Just realized that a MAP sending unit  (which it compares for difference in throwing the Code) may work better than the resistor, and I have an extra one.
The tracker does not launch quite like my Grand Prix with the 3.8 V6, and I have not just floored it on take off, not the intended use.  It had started Washington rain (just under a drizzle) and I was in town with the Tracker and I poked the throttle a little heavier than usual acceleration and Tracker wrapped up, both Tach and exhaust sounds, while just sitting at stop sign.  It started to move when I let off.  So when I was driving at 30 mph in Power mode (shifts more agressively) I snapped the throttle and watched the tach and speedo move rapidly, transmission shifted a gear and I was still going about 30.  It will take a very light throttle in the snow I am thinking.
I have mocked up my hood changes on a beater hood, and will look great when done on the good hood.  Whole thing needs new paint, as pink door from last trail run (last year) just is not right.

Thanks for the update!

I will post up some photo's when I get the hood done.  Going to have cracked wind shield removed, then paint it and have new w s installed with outlet pipes for the exhaust.  Can't wait to make it my DD again.

where ya located at?..id love to take a look at your project...im in portland oregon,..just got done with a 1.8l motor swap in my 94 tracker,..been working on re-doing the 3-link in the rear on mine

I am in Bow, Wa.  about 60 miles north of Seattle. 
Always ready to show and tell, except in the garage (it REALLY needs a clean-up).  And would enjoy a reason to make a run, but don't think my wife would enjoy a run clear to Portland.  We really need a Big Run up in this area.  There are quite a few regulars close to us.

I had modified my 3-link before I did the motor switch, and then did a 4-link during the swap.  I have enjoyed the ability to just goooo when I wanted to, but have not realized how much go I have.  This weekend I drove a 4 door 16v, and quickly got used to 4,000 + shifting and watching for a large space to pull out into.
How is yours with the new power?

im loving the new power...gets up and goes great..i raced a bone stock 4.0 jeep wrangler and he was quite amazed when a GEO beat him on 33's...lol

i had hood clearance issues as well,..i used the sport radiator and it was too big...had to cut the round crossmember off the front and put a piece of angle a bit lower..i totally didnt want a body lift!!!...i ended up using hood pins

heres a recent pic

You engine compartment is a little fuller now.
I have been ignoring the hood for now.  Got to get back in the shop, but it was sooo nice when I got the Tracker on the road.
What are your axles?  Yota's?

i used a samurai axle up front,..the only reason i did a sas swap was i broke a c/v axle and decided i wanted to lift it...sas was the cheapest way to get a lift and replace the broken c/v all in one...for now the sami axle will be strong enough for 33's and light wheeling...if i find a smoking deal on yotas and actually have the money at that time,..ill switch to yotas,..thing is, it cost too much to build up a set of yotas...

  i also like that this is still all suzuki

Have you gone to moly axles, or are the stock ones holding up with the 33's?
I just looked through your build, nice work.   Didn't see anything on the 1.8 though.
Are you going down to Zukfari?

ive got a buildup that includes the 1.8l over at zk...i need to work on the thread over here...lazy i guess...still running stock inners for now...im just carefull...this summer ill upgrade to cromo's..as far as zukfari,..i havnt made any plans yet....