That's a brilliant thought there, sir lance!  Hadn't thought about that one.  It's got to be something along those lines.  Blatantly obvious... but taken for granted because it is so obvious.  

Can anybody come up with a different part number for the 2.5 vs. the 2.0 master cylinders? I am told by both dealerships that they interchange.

I don't have access to Tracker info but on the Suzuki SQ420 & SQ625 the master cylinder part numbers differ based on the year and with or without ABS - I'm seeing four (4) different numbers, however I have no details  as to whether they are interchangeable or not.

I just took apart my original mastrer and one of the new ones. They are identical in every way shape and form. I was a machinist for 17 years, I checked every dimention I could. I think these are the same. I know the original master worked at one time, not all that long ago. Boy I sure wish it still did! :'(

I have brakes!!!
It just so happens that my dad's neighbor teaches auto mech at the local tech school here. 30 some years of knowing the guy and I never knkew what he did?? Well, I went on vacation and dropped it off at my dads so neighbor dude could look at it. My dad calls me and says he got the brakes working, it'll cost me $4.00 for the part, and we'd discuss the rest when I get home. It seems that both calipers had 1 bolt frozen, or almost frozen. With one line plugged, it'd have the pressure to move 1 caliper, either 1. He broke 1 bolt, saved the other and they work just fine now. I can't wait to go back to Boucher Cheverolet and Lynch Chevy as well to talk to their mechs. I feel stupid about it, but they both should have found that problem. That update will come in a few days, I'll keep ya's posted.

YEAH!!!!  Glad to hear it!  Now here's another factoid for us when we get stumped on our trucks.  Give that guy a quality cigar and a six-pack!!  Your problem was getting a bit spooky.

oh good, now i can stop racking my brain out a few times a day thinking about what the problem is, it was starting to piss me off lol