Well after a loooooong time of saving up for a major rebuild of my track kicks 5-speed.  I was lucky to find a decent 5-speed from a 90 tracker locally at the wrecking yard for $200.

I jumped on it and had it installed on my 1995 16v.  It runs flawlessly except just one new issue....
Highway speed.

On my 95 i could put in 5th and cruise 75 all day and it would sit in a nice spot between 3000 & 4000 RPM.  it ran fairly quiet and comfortable.  This new tranny however is bouncing off 4000 RPM at just 70mph, 4500 RPM at 75mph and is louder than all hell because it's revving so hard now. I'm glad to have my tracker back in action and the 4wd working again, but it's a rough trade off because i do a lot of highway driving.

Did Suzuki change the gearing in track kicks somewhere inbetween 1990 and 1995?  Or does my local tranny shop need to make an adjustment of some sort?

I thought the change was in 96.

I thought the change was in 96.

i thought so too, but i have seen yr numbers get changed by DMV and auto dealers
bought a 94 once that was titled as a 95

I think the it was the 8v that had different gearing from the 16v. did your new gearbox come from an 8v?

Well being that there was not a 16v motor till i believe 1992 or 1993 I'm going to guess it was an 8 valve tranny.  Dang you may be right, this kinda blows.

I was hoping they were all the same.

put bigger tires on it!!

That's funny.  I was thinking the same exact thing.

The problem is your replacement tranny came from an 8V trackick.
The 5 speeds that are found behind both the 8V and 16V engines have identical gearing EXCEPT.....
for the 5th gear ratios.  The 16Vs have a .795 5th gear ratio, the 8Vs have a .86 5th gear ratio.....which translates into about a 300 RPM difference at 60 MPH (and gets higher as the speed increases).

is it realistic to think i could have that last cog replaced to the proper one?  Or would that be more $$$ and troble than it's worth?  Or would be more cost effective to just swap in the correct tranny later down the road?

because this is my DD and i do so much highway driving it's not economical for me to run this tranny in its current form.  so a 5th gear change or full tranny swap will need to be addressed eventually.  The other thing is i DO plan to lift this truck so maybe the lower gear will help on the highway once 30 or 31's are applied? maybe?

i don't want to thread crap but i have a 1990 8v and i do a lot of highway driving would a manual tranny from a 16v bolt right up

Is there much difference in mileage? with the slightly lower gearing the engine won't be working so hard. I doubt that it would be costeffective to strip the trannt and replace the gears, if you are planning on fitting larger tyres later then you will most likely be better off with that tranny.

It would be easier to just swap the transmissions.  I believe the only difference is the 16v has a couple of extra ears.  They do swap across models.

Could be wrong on the ears though.

8V and 16V trannys interchange (as jookycola found out).  The 16Vs do have some braces that run from the engine to the tranny, but you don't have to use them......if you decide to run an 8V tranny on a 16V engine or a 16V tranny on an 8V engine).

8V and 16V trannys interchange (as jookycola found out).  The 16Vs do have some braces that run from the engine to the tranny, but you don't have to use them......if you decide to run an 8V tranny on a 16V engine or a 16V tranny on an 8V engine).

Exactly.
It was a direct bolt on and runs flawless and strong with no problems.  However, the highway gear (5th) is seriously low for the 16v motor.  Which i guess is good news for 16v owners looking to lift their rig and put on bigger tires and heavy accesories. 
If you drive a 16v with factory tranny you're used to cruising at 75mph on the highway comfortably at 3000 to 3500 RPM easily.  With the 8v tranny attached to it you will now reach 3000 to 3500 RPM at only 55mph...75 is a noisey 4100 to 4200 RPM.