What's the difference between these (other than the expected cosmetic updates)?  They fall into the same body family (by most, as evidenced by this forum section), but they're listed separately by some.  I guess what I'm looking for is any notable differences in drivetrain, suspension, or body/frame.  Thanks again ~

I'm not aware of any differences that could be labeled major (frame, suspension, drivetrain, etc.), except for the steel front axle housing, and the slight bump in horsepower (2002, I believe).  Early automatics 99-02 (I think...but don't quote me) had aluminum front axle housings.  Manuals always have steel.  Somewhere in the later models, they went to all steel, but I'm unsure if it was in 2003,04, or 05.  It is my understanding that at least the 2005 auto GVs have steel, but you'll want to verify that.  Suzuki is known for using a billion different parts on similar models. 

I believe the GV got a higher capacity, or at least a much more efficient air conditioning system around 2002-03, although it might have even started by 2001.  I would consider this major, living in Florida and owning a 1999. LOL. 

I once found info stating that the 2005 received more sound dampening materials (versus even 2003 and 2004), but I cannot vouch for the authenticity of that statement. 

I think the 2005 has a different alternator (possibly a little larger) as well.  At any rate, I believe that this vehicle was truly perfected by 2005, and would love to buy one in the near future.  Every thing is a little better on the 2005s...better rims, great AC, no timing chain problems (though my 99 has 200,000 miles with no problems), possibly quieter, steering wheel audio controls, 165hp, better looking dash (2003-2005).  About the only thing I don't like are the silvery, aftermarket-looking, tuner-esque taillights.  I much prefer the traditional taillight look. 

Oh yeah....one other MAJOR thing (how could I forget?).  Many 1999 and 2000s (including mine) had a faulty front 4wd actuator system.  Slips way too much when in 4wd on a slippery surface and makes many loud banging thuds...a MAJOR PROBLEM!  Chevrolet issued a bulletin on this for early Trackers.  Suzuki never did a think.  Do yourself a favor, and try to get an 05 if you can.  Otherwise 2003-04 are nice, too.  Hope this helps a little.  I used to remember the dates when things changed on these trucks, but I've been out of the loop for a while and have forgotten.  Good luck.

uhhhh - not all the manuals have steel (cast iron actually) front axles - mine has aluminium.

As far as the front axle free wheel actuator goes - Suzuki has issued TSBs, there are at least two, and another one for the transfer case - there are two different problems with similar symptoms - banging noises in 4WD can be caused by both the front axle and the transfer case, if it's the transfer case it will also jump from 4HI to 2HI when it goes bang.

mine has aluminium

But aren't you a 4-cyl and not a GV?   

That may be the difference.

Well you see that's the thing - GVs DO come with 4 cylinder engines - just not in the USA.

Suzuki sold the Grand Vitara with the 1.6 liter G16 engine (3 door only), 2.0 litre J20 engine (both 3 & 5 door) and the 2.5 liter H25 engine (5 door only).

Even with that - to the best of my knowedge the US market V6 GV with the manual transmission did ship with aluminium front axles - and in fact a quick perusal of the EPC confirms that the early US spec GV (SQ625) uses the exact same part number axle as my Africa spec GV (SQ420), which as I said earlier is aluminium.

....Suzuki has issued TSBs, there are at least two, and another one for the transfer case....

Fordem, have you got a link to those TSB's, please?

TSB / Service Bulletin info here:
 http://www.auszookers.com/index.php?name=Forums&file=viewtopic&t=4947&postdays=0&postorder=asc&start=0

the US market V6 GV with the manual transmission did ship with aluminium front axles

"Ship" as off to other markets? My Canada / CAMI assembled V-6 GV has steel axle housings, is why I ask.

Hmmm...I've never seen or heard of a US Market V6 Grand Vitara 5-speed manual with an aluminum front axle housing.  My GV is a first production year model, and has the cast iron.  I've seen many more like it, all with cast iron, and even consulted Suzuki junkyards.  Perhaps they sold them in Canada, the Bahamas, or some other nearby market with aluminum housings.  Anything's possible, I guess.  At any rate, it's something to look out for.  Cast iron is the way to go, for sure.

As far as the front axle problem, I would love to see a Suzuki-issued TSB on the actuator.  There may be one on the transfer case (which wasn't my GVs problem), but I've never seen a TSB for the faulty front actuator, other than the one issued by Chevrolet, not Suzuki.  Chevrolet acknowledged the problem....Suzuki never did.  If I'm wrong on this, please show me, as Suzuki pretended it was a normal part of the 4WD system in my discussions with them, and I went on to spend a fair amount of my own money to fix it after finding the Chevrolet-issued TSB.  Somewhat annoying.....