I've owned 3 Samurai's, and 2 4-door trackers (29" IFS on OME, and 35" SAS). I'm getting to a point where I'm starting to out-grow the little 1.6L 16V. I've looked into the cost of a swap - and it seems like it would be cheaper to just get into a 1999+ tracker with the 2.0L or 2.5L already in it. If I go this route, what kind of lifts & gearing options are available to me? Will I be able to do dual T-Cases? I've tried poking around in there, but I don't see an FAQ???

My 2 cents... if the body and frame on your current truck is in good shape (ie; little to no rust) I think I'd lean towards slipping a 2Liter into your truck before buying a 2nd generation truck.  In almost all cases you are going to spend $4-5 grand JUST to buy a 2nd gen truck... THEN you're going to have to invest additional cash into buying parts to build the new truck's suspension, skids, wheels and tires... which will cost another $2K... unless you put a straight axle under it which will be another $4 grand.  Oh yeah, and the after market hasn't caught up with the newer trucks where the front end is more limited because of the shorter arms and R&P steering.  More is available for the 1 generation trucks.. like more choices on differential locks, bumpers, etc.

IF your truck body is in good shape a 2 liter upgrade will be much cheaper in the long run and you still have an awful lot of venders selling after market parts for the 1st generation models that are not yet being made for the newer trucks.   Sean DeVinney has an article on his 4X4 AFTERMARKET site where he did a 2Liter install into a 1st gen truck using a wiring harness kit modified by the Trail Tough guys (as I recall) which simplified the install.  They also sell a radiator for the upgrade which made it all work that much better.  Besides, I've owned three of the newer trucks and there is still alot of things about the older rigs that are appealing to me (I owned four of them)... EXCEPT the 1.6 liter engine that came in them.  A first generation truck with a 120HP engine in it would be THE bomb (me thinks).  They are still sharp looking little trucks!  The best of both worlds.  If money is no problem, then disregard all of the above.

Norm

Lift wise, Calmini offers a 2.5" suspension.  Rocky Road has a 2" B/L, same with SKY.  FTS has alot cool stuff (read the thread on it). Old Man Emu has 1.5" springs and lift struts.  Zukination has a big susp kit in development.  Also you can use coil spacers same as the 1st gens.  If you don't mind paying alot on shipping there is alot of cool stuff in Australia and  the UK.  As for gearing there are alot of recent threads  about it.. Seems like everyone is pretty much putting in trackkick gears with a rear lockright.  I'm still a noob so I don't know much anything about T-cases! 

My 1.5" and 2" coil spacers will fit the 99+'s but my strut spacers will not.

Jeff - is strut mount flip an option on these?

I'm not 100% but I don't see why not. The difference is the strut mount is larger in diam. thus my spacer is too small. The design is the same so the flip should work. 

You can't flip the mount.. its to deep. Seems like you  can only do strut extenders, strut spacers, or just longer struts with these. 
Jeff you should get with Uncivilized about the measurements on his strut spacers..http://www.zukiworld.com/forum/index.php?topic=22823.0   Throw in some hardware and maybe a set of 2" shock extender.  Then you could sell the first "budget" complete lift for the 2nd gens!

Will do, thanks for the link.

Glad to see this thread now before the spacers came in. I was waiting to get them and was going to start on it right away. Now I know I have to order some strut extensions before I rip into it.

Good luck.. my strut extenders are still sitting in my shed. Even after to two pipe wrenches and some serious grinding I couldn't get them on!

Good luck.. my strut extenders are still sitting in my shed. Even after to two pipe wrenches and some serious grinding I couldn't get them on!

Where did you buy them from? I don't want to order from there too.

boondox..  others have been successful with them!

Nprecon,
Thanks for the tip. Here's my thoughts though: I love my kick, but I don't like the lack of power. The 2.0L swap looks appealing, but it looks like the swap is going to cost about $2000+. If I can sell my kick for $2000-$2500, and get a newer generation for $4,000-$5,000 I've 'upgraded' to the 2.0L AND it's easier to find a Gen 2 4-door with auto and A/C (you wouldn't believe how rare that is around here - don't know why). I can be happy for a long time on 29" tires while I buy stuff to go IFS on Toyota axles... as long as I have enough power to turn them. Right now on 29" tires & the anemic 1.6L I'm getting the SAME gas mileage as my GF's Nissan Xterra with a powerful 4.0L V6! And, let's not get started about trying to accelerate up the mountain loaded down with camping gear... forget 5th gear *sigh*

So, to make a long story short, I'm considering the 2.0L engine or the 2.5L V6 - but for the price - it seems to make sense to just get the 2nd Gen instead of doing the engine & trans swap???

Perhaps I should be asking: Who's got bigger tires, and how did that impact your MPG, power, acceleration etc? In my 1st Gen 4-door the 29" tires hurt significantly. It's drivable, and fine as a DD / weekend warrior, but I don't know how the guys on 31"+ tires do it!

Here is a recent thread on MPGs..http://www.zukiworld.com/forum/index.php?topic=23145.0