hey all,
been considering getting a GV as an adventure rig and well because I have the Evil Seed sickness and can't stop the obsession with zuks. We recently introduced our 18month old to 4 wheeling and he seems to love it and will spend hrs in the truck just sitting and playing turning knobs and what not. 

So I have been considering getting a GV as an adventure rig and a more family based rig. One would assume you would go after the last year the model produced and find a GV with the lowest miles you can.

So that is the question to you guys on the forum. What changes has suzuki made that make some years less desirable than others. The only thing I know for sure is the 99 manual transmission has the cast iron front end.. Which is a good reason to go for that year but those parts are attainable and a direct swap should I need them.. What else has changed from year to year.

thanks
Hutch

for what two cents i have lol, earlier is better because more drivetrain accessories (lockers and other things) are available. Depending on where you live rust can be an issue and 2.5 V6 isn't what its cracked up to be. My 02 tracker averages about 18-19 city (15 minute commute at around 55 avg. MPH) and about 21 hwy. If you can find a Chevy Tracker instead of a Zuk a ZR-2 appearance pkg with a 2.0l is a good option because you would have your skidplates already. thats all i got.

Early versions (98~99) had problems with the front axle freewheel clutchslipping under load and the transfer case jumping back from 4H to 2H, both problems were resolved on the later years (02~), later versions (03~) had many of the separate controllers integrated into a single BCM (body control module).

I would go for an 02 or an early 03 (if it has horizontal AC slide controls it's early, if it has three round knobs it's late), and I prefer the 2.0 to the 2.5.

X3 on the 2 liter engine.  I have not owned a 2nd gen GV to date, but I would also recommend the 2 liter engine over the 2.5 V6.  I've owned three 2nd gen Trackers, two with a manual transmission and one with the auto transmission.  I have driven a ZR2 Tracker with the 2.5 and the auto transmission.  Performance wise, (acceleration and additional "grunt") I can not say the 2.5 provides enough increase in performance to justify it over a 2 liter (to me).  The extra fuel economy the 2 liter engine provides is a plus that just keeps on giving and when it comes to engine repairs such as timing chains, gears and water pump replacement, you will generally spend less money and time as well.

If you intend to modify the truck (with larger tires for example), there are diff gear sets available from other models that can help you off-set the loss of mechanical advantage.  The 2nd gen body style and front drive train somewhat limits the modifications you can do with them without major modifications and expense, but they are still quite capable out of the box, their ride is much nicer and the extra room in a 4 door (for kiddies in your case) would work well.  

But, as ZR2Tracker Joe mentioned, Chevy did make the early ZR2 models in a 2 door also.  All of the above applies except the extra room of course.  As with all of our older trucks, they are becoming difficult to find, but they are still out there to be had.

Don't forget that in '03 (i think it was '03 ) the trucks had the interior, especially the dash re-designed.

If yours is going to be a bush truck, then maybe you don't care, but i always thought the new layout was a lot nicer then the original. Just my two cents.

Oh and X4 on the 2 liter engine. Enough power, good mileage, reliable and easy to work on.

Yes - that dash redesign is what marks the transition to the BCM - the old dash has the a/c controls horizontal and above the radio slot, and a single DIN radio with a clock below it - the new dash uses a double DIN radio which is above the a/controls.

It may be just me, and this may  be strange since fixing electronics is what I've done most of my life, but having the BCM puts too many controls into one device - turn signal, a/c, power windows, power locks, - and if the BCM goes you lose it all.

That's interesting about the new dash controls and BCM for the '03 GV.  I'm thinking the '03 and '04 model Trackers never migrated to the newer (Suzuki) controls... probably by plan because the partnership ended with Chevy after the '04 model year? 

Can't really comment on the Trackers, we don't get those here, I have learned through this and other forums that there are wiring differences between them and the "matching" Suzuki, so you'd nned to actually check behind the dash for the BCM to be sure.

2005 automatic all the way.  Nicest interior/dash on 03-05, but they also added more sound insulation and steel front axle housing exclusively for all 2005s, as far as I'm aware.  On earlier ones, only the manuals have steel front housing.  Interior materials are much nicer, and you get audio controls on the steering wheel for 2005.  Early ones have timing chain tensioner issues, as well as faulty front diff 4wd actuator (around 99-2001).  2005 is the pinnacle, and should still be the same as 2003-04 for lift kits, accesories, etc.  There are some really nice alloys on some of the 2005 ones, too.  Don't be afraid to go up to 100,000 miles.  These trucks go forever.  Oh yeah, you'll get a little more hp out of the 03-05 as well (165 v.s. 155).

Full framed or pan framed on the 2005s?

What's a pan frame?  98~05 are body on frame construction, 06 and later are monocoque.

That's what I was wondering - that the full framed body styles were in production through the 05 model year.  Pan frame - monocoque = frame molded into the the bottom of the truck versus setting on a separate full frame construction.

Yeah...2005 was the last year of body-on-frame (although, somebody needs to let CALMINI know...their lift is advertised as 99-04...duh...  ).  I'm sure that there weren't a lot of 2005 GVs sold, but this is the truck that I would want.  I have an Aerio SX that has the same climate controls, and I like them a lot.  I think the interior looks pretty sharp, and you would be getting the last model year body-on-frame truck that Suzuki made for the US market.  I see some pop up on Autotrader every once in a while with as little as 30,000 miles.  I think they would be a great value 4x4, since they can almost always be had for $7000 to $13000.  It's questionable whether they would accept the Lockright/Sidekick rear diff assembly, though.  Even my 1999 doesn't allow the Lockright to unlock correctly....