Build Hot Girl Summer - 96’ Geo Tracker UTV Build

ReadSpeed

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Apr 7, 2026
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Hello All,

My name is Ted. Long time listener, (I browsed the old site 15+ years ago every day in middle school) first time caller. I spent my youth reading Peterson’s 4x4 cover to cover, dreaming of going on the Ultimate Adventure or competing in TTC. Life, per usual, had other plans for me.

In high school I never had the money for an extra vehicle, so a dedicated 4x4 was never in the cards. I attended UNOH for college, where I became engrossed in the car world. Leaving school, I landed a job restoring exotic cars. Having access to tools/lifts/suppliers I kept right on down the car-road and after paying my student loans off I went through several “fun vehicles”, my last two being an E36 M3 and a Ferrari 308 GTS.

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Fast forward a few years and life again threw me a curveball; I sold off all my toys and opened a business. A mobile welding and fabrication outlet, specializing in motorsports work. After several good business years, my wife and I were able to purchase property and build myself a shop. These two details will be important later on in the series. At this point I am sure you are bored with my life story monologue however, so I will move onto the fun part. I have almost 4 miles of trail on my property that is primarily used for dirt bikes, and I live in an area that most would affectionately refer to as "the middle of nowhere". All of the pieces to the dedicated 4x4 puzzle finally clicked.

I had a very specific set of requirements, I wanted something that was roughly UTV sized, 4 seats, 4x4 (obviously) and weighed under 3500 lbs (NH's OHRV registration weight limit). As you might imagine, there aren't a ton of vehicles that fit these prerequisites. I ended up stumbling across a 1996 Geo Tracker a town over and after a few months of pestering the owner I was able to secure it for $500 delivered to my house. It was a pristine (or close enough in the rust belt) example of a Tracker, with two small holes in the outer rockers, faded paint, but otherwise in immaculate shape underneath. Nary a scuff in the factory undercoating on the frame or floors, brand new 30" Duratracs, new KYB shocks and 2" pucks. It was perfect. Well, a perfect start at least, as it was 2WD and didn't come with a key. Minor problems, minor solutions.

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I removed the ignition cylinder, got it running and driving only to find it had a horribly blown head gasket, and I also believe the valve seals are gone as well. Business picked up over the winter, so I pushed it outside and covered it behind the shop awaiting a solution. I schemed up a plan to hunt down 4x4 parts for it over the winter and added it to my list of marketplace searches. Alas, Tracker parts in the Northeast are few and far between. Last week however, I struck gold and found 1996 Tracker 4 hours away, that allegedly had no issues aside from a dreadful case of cancer.

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8 hours later, I had secured my second Tracker. It is indeed rusty, someone did a horrendous job repairing the rockers and floors, but the drivetrain purred like a kitten, and it has 50k less miles to boot. The perfect donor. With a donor in hand, it was time to formulate a plan. A plan I will save for another post as I have likely bored you poor readers half to death by now. If you have indeed made it this far, I applaud you as well as thank you, I am ecstatic to finally have a 4x4 build and look forward to hopefully entertaining you folks (and shamelessly promote my business in the process) along the way.

Cheers,

Ted
 
You went from not being able to afford toys, to a Ferrari AND a BMW, to a geo tracker in your first post. This is going to be awesome.
It’s been quite the journey! If it’s any consolation, I paid more for the Ram 3500 pictured than both the Ferrari and BMW combined. They were both pre-covid purchases, and needed there share of work to get to the state they were in when those pictures were taken.
 
Have you followed any of the "sxs" zuk builds on here?
I have not run across any on here that have caught my eye. I’ve seen several body swapped/UTV merges on the FB groups though.
 
Just a few that I remember, not all are 100% a "sxs build" but good tech either way




My 2 attempts, first one was mostly what not to do :laughing:

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I am a firm believer that every good build has a plan behind it. With every plan there should be an intended goal. I mentioned TTC/ultimate adventure in my previous post and while both of those events would be cool to do, it’s highly unlikely this will evolve into something as a wild as necessary for those types of things. While I have much more modest intentions, I think I have some pretty neat stuff planned.

So the goal here is to have a capable, street legal UTV, that I can pick up fallen trees on my property with, clear new trails, ride the rail beds/UTV areas, and cruise to the local ice cream shop with the top down (my wife absolutely loves getting ice cream). Quite modest intentions.Like most people, I operate on a budget. Having blown most of my money on the shop and current house build, this will start as a pretty tight budget build.

With all that in mind here are my current (likely to evolve) plans:

•Reseal donor tracker engine
•Manual/4x4 install on white tracker
•Front diff brace
•Swap nice soft top on white tracker
•Lockright rear locker
•Vevor 13k lb receiver mount winch box
•Front brush guard, skid plate, and frame reinforcement
•Rear tube bumper with receiver
•Rear half cage -external
•Rock sliders
•Rust repair on rockers
•6 seater conversion

I have all the tubing/sheet to complete the cage portions and bumpers. I’ve got some leftover harnesses from a previous car as well as the seats from the donor. My plan is to drive it this summer so I have a few months to knock out the running/driving portions and I’ll likely plug away at the cage bits this winter as well as any weak links I find. Simple and effective, and hopefully garner enough local attention to gain some other off-road business from folks.

Cheers,

-Ted
 
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Just a few that I remember, not all are 100% a "sxs build" but good tech either way




My 2 attempts, first one was mostly what not to do :laughing:

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Looks like I have some reading to do! Thanks for the links!
 
Welcome aboard.
I’ve got the majority of a 4wd swap documented here.

Personal opinion. Sell the 2 trackers and get a v6 grand vitara. Tim Hardy had one on 33's and you'd be way happier/better off to do so.
 
No problem

6 seater.......?
I’m going to put a removable bed extension in the trunk that integrates with the cage/bumper for hauling wood that will double as room for 2 extra rear facing seats. I’ve got 2 nieces and a nephew that absolutely love riding around in our gator UTV so I think they will like this.
x2 Agreed, I am a closet tracker lover!! I have a jEep I built long ago and would really like to have a tracker as well!!
We have a JL 4 door wrangler and it’s pretty cool but there’s nothing like a small light rig!
Maybe when the 30’s wear out. They are brand new, I’d hate to spend more on 33s than I did the whole car before I got some use out of them.
Welcome aboard.
I’ve got the majority of a 4wd swap documented here.

Personal opinion. Sell the 2 trackers and get a v6 grand vitara. Tim Hardy had one on 33's and you'd be way happier/better off to do so.
Grand Vitara is too heavy to be registered as a UTV in NH, the tracker however is not. They go by GVW here and you need to be under 3k lbs.
 
Stick with 30s imo. The guys who did 30s had little to no drama making them fit, and just went out and had fun. I tried 32s and they just caused a lot of issues with modifying the ifs.
I can definitely see larger tires becoming an issue quick. The green Tracker has 235/75s and they rub the rear fender lips when it articulates at stock height. The 2” pucks and the 225/75s clear at full articulation in the rear on the white tracker however. The front positive camber is causing issues but I will likely slot the struts when the time comes to solve this as the eccentric bolts were not enough.
 
The Donor:

As mentioned in the first post, I spent a good part of winter trying to find individual 4x4 parts to swap into the white Tracker, to no avail. They certainly aren’t as popular as Tacomas it seems and after losing out on a couple marketplace deals for complete cars I was nearing hopelessness and contemplating finding something else to build.

I decided to throw a hail Mary and toss a WTB post on a few of the Tracker oriented FB groups and see what popped up. Had three fish on the line by the end of the day and unfortunately the only one that was willing to make a deal just happened to be the furthest away.

Having lost out on a few deals this winter, I locked down a date, loaded up, and set out for the far reaches of Northern NY. It was a gorgeous trip on the ride out, I chose to forego the ferry and go above lake Champlain. I did end up losing my trailer plate and had to have whacked something on the return trek as I lost all lights on the trailer. Aside from that and diesel being $6/gallon the trip went pretty well.
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I was able to drive the green tracker briefly before buying, just enough to ensure the transfer case shifted and it went through the gears fine. It did have a sizable fuel leak from the return line so I quickly loaded up and headed out. Initially I could tell it was rusty but I had hopes of salvaging the shell and perhaps just selling my white tracker. Having done plenty of rust repair, I wasn’t all that concerned.
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After rolling it off my trailer, I jacked it up to get a better look and hopefully repair the fuel line to put some miles on it. Looking at it closely, I could tell right away this was not worth the time (my time at least) to save. The rockers were 4x4 square tube, sort of welded, sort of fiberglassed to the door sills. There were several holes in the rear and front wheel wells. There was absolutely nothing left of the driver’s side floor pan/foot well area and someone had already grafted floor pans onto the old ones. The trunk floor looks like Swiss cheese, and the front shock towers are being held together with some dry rotted fiberglass as well. The time and money to save it was far from what I was looking to invest, especially with how nice the white one is.

Despite the obscene amount of rust, it took $3 worth of fuel injection hose to make this donor a good runner. I drove it down to the local gas station, traversing a few dirt roads as well a 55mph zone all without hiccup. I did break the gas cap tightening it and there’s no radio to drown out the road noise coming through the floor. Fortunately it does wheel pretty well for a completely stock rig on just some dry rotted tires. We did some testing last night out back, and I’m quite pleased with the purchase. Total invested for the 2 cars so far and fuel to pick up is $1289.

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Should be fun build. My dad had one of these for a short time when I was a kid and we wheeled the local reforestry station before they banned vehicles.

I've looked at em but up here on the Canada side of that new York sign those would have went for $3-5k haha.
 
Post the share of work you had to do to the Ferrari pls somewhere else in the forum. :beer:
I will have to do some digging, I’ve been spoiled on some of the fun projects I’ve been a part of. I will drop some random projects in here in between my Tracker Shenanigans, but if you’d like to see my other work more frequently you can check out my socials :
@readspeedllc on both FB/Insta or check out my website readspeedllc.com
Should be fun build. My dad had one of these for a short time when I was a kid and we wheeled the local reforestry station before they banned vehicles.

I've looked at em but up here on the Canada side of that new York sign those would have went for $3-5k haha.
The pricing definitely seems all over the place if you’re not in the rust belt. I’ve seen some nice 4x4 examples in the southern states listed for 10-15k which is absurd to me when you can get 4 rotten F350s for that price!
 
Having never worked on a Tracker I browsed YouTube and was delighted to find there were several engine removal videos available, even a few step by step guides. A guy with an obnoxious green tracker was the most thorough so I followed along his guide as I went through.

Being a southern car there were no real corrosion issues. The harness plugs were definitely brittle but I was able to pull everything without breaking the clips. I was not able to pull the fuel line at the frame rail but I was able to snake my way between the fire wall and detach it from the rail.

The only real trouble I had in removal were the torque converter bolts. I don’t believe they had ever been removed before and no matter where I placed them in rotation I was not able to get a straight extension onto them. I managed to get two of them removed with a shorty socket and ratchet but the third would not budge. And I’m talking an 18” handled ratchet. I tried one of my wobble extensions and it would not budge on my half inch air impact. I pulled the muffler out of the impact, cranked my compressor up to 160psi and sheared the anvil off the extension. The bolt was starting to look rounded so rather than completely strip it and half to break out a die grinder, I pulled the pan and the pickup and was able to buzz it right out with a regular impact socket. I imagine that if it had been 4WD, pulling the pan probably would not have been possible without lifting the engine up.

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With all the bell housing bolts out I was able to separate the engine/transmission with a few wiggles and hoist it up out of the way. I’ve got a 1 ton gantry crane in my shop that made this portion a breeze. I pulled the hood before I started just as a precaution but I think it would come out without having to.

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Long story short, no progress on white car yet. It’s been a busy spring, I just finished up caging a Tacoma and a few Imprezas so it’s nearing time to start stripping the green car down to a shell to be scrapped.

In the meantime I figured it was pertinent to beat on the green tracker to see if I could find some immediate weak points. First and foremost, the cooling system is pretty subpar. Once the car is heat-soaked at low speeds the little electric fan and clutch fan aren’t quite up to snuff. I’m going to check to confirm the fans are in fact coming on but there’s not even a shroud for the pusher fan so that may be a good place to start.

Next up was the clutch In the green tracker will get warm in the rocks. If I had to guess it’s stock and there were several options on rock auto for replacements/upgrades. I figured it was a good idea to do so while I have the transmission split from the engine anyways.

I plan to also do the EGR block off/delete while the engine is out as well as the valve cover and oil pan gaskets. I’ve seen some sort of water plate on the back of the engine that I’m going to do as well just for safety.

On a funnier note, we took the green tracker up into some of the single track we ride dirtbikes on and it did amazing. My wife loved having the power steering compared to the gators manual steering. She did come down hard on some rocks and ripped the rocker and front fender off the driver side as well as took out the tire. Minor problems considering she enjoyed the heck out of the adventure so I will take that as win.

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Any clutch is going to suffer. Suzuki's have **** low range stock. Some 4.24:1 tcase gears will be a huge improvement. Or stick with the auto when you fix up the white one.
 
Any clutch is going to suffer. Suzuki's have **** low range stock. Some 4.24:1 tcase gears will be a huge improvement. Or stick with the auto when you fix up the white one.
Trail gear’s 4.24:1 kit is the same price I paid for the whole Tracker, a little more if you factor in shipping. Definitely on the list, definitely not going to happen this year though. Unfortunately the auto is a 2WD unit, I’d have to swap output shafts and tail housing from my research to allow the transfer case to bolt up. When I finish up my apartment unit I’ll have more “fun money” for these sort of things haha.
 
Trail gear’s 4.24:1 kit is the same price I paid for the whole Tracker, a little more if you factor in shipping. Definitely on the list, definitely not going to happen this year though. Unfortunately the auto is a 2WD unit, I’d have to swap output shafts and tail housing from my research to allow the transfer case to bolt up. When I finish up my apartment unit I’ll have more “fun money” for these sort of things haha.

Ya, but it'll be the best money you'll spend. Nothing worse than burning the clutch and beating yourself up with too tall of gearing.

Could look at what JR4X did with putting a divorced Sami tcase behind the 2wd auto. The big gain is the lower high range (1.4-1.7:1) and variety of low range kits (4.16-6.5:1)
 
Trail gear’s 4.24:1 kit is the same price I paid for the whole Tracker, a little more if you factor in shipping. Definitely on the list, definitely not going to happen this year though. Unfortunately the auto is a 2WD unit, I’d have to swap output shafts and tail housing from my research to allow the transfer case to bolt up. When I finish up my apartment unit I’ll have more “fun money” for these sort of things haha.
Wait till Black Friday. I got my gears like $100 off and if you buy them through summit you get free shipping
 
Ya, but it'll be the best money you'll spend. Nothing worse than burning the clutch and beating yourself up with too tall of gearing.

Could look at what JR4X did with putting a divorced Sami tcase behind the 2wd auto. The big gain is the lower high range (1.4-1.7:1) and variety of low range kits (4.16-6.5:1)
I like that idea, I’m keeping the auto so maybe that can be done in the future if I run into clutch issues on the first setup. It’s not really a hardcore wheeling rig as I’m sure a lot of the folks on here do so hoping to get some life out of a new clutch.
Wait till Black Friday. I got my gears like $100 off and if you buy them through summit you get free shipping
I’ll see where I’m at come November, I plan to do the cage the remaining tube work this winter as it is.
 
Finished up all my customer work for the week and had a spare hour this evening so started to strip the green Tracker down. Pulled the front and rear driveshafts, getting covered in transfer case fluid in the process. I also pulled the exhaust out which was already broken and rotten in several places so the ol’ M18 Hackzall got put to work. Someone was kind enough to weld the entire exhaust as one piece so it had to be cut anyways.
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Since buying the green Tracker, the hubs have always been seized in the locked position. Not a huge concern for what I do but if I’m going through the hassle of swapping parts I’d like everything to function as it should. After pulling the drivers hub out I can see why they didn’t move.

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The passenger side inner portion of the hub is stuck on the axle and in even worse condition. I’ll have to get to it when I pull the wheels off.
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It looks like there was grease inside the hubs at one point, probably 30 years ago when it rolled off the lot. I’ve never owned anything with locking hubs, my Ram uses a driveshaft disconnect so this is a first for me but rather than taking the time to disassemble them every time the rig sees mud/water, I think I’m going to drill and tap the inner hub body for a zerk fitting and make them grease-able. What say ye?
 
Pack a lock out full of grease and it won't work, just takes a light coat.
Freshly serviced hubs last good long time.
Gear oil gets changed when in deep water,
Down tube on a stock Sami is 2 wall, not sure about kicks, inside tube comes loose, rattles a lot and blocks ****.
 
I think I’m going to drill and tap the inner hub body for a zerk fitting and make them grease-able. What say ye?
Don't. The seals go bad over time. replace them and put a light coat of grease in there.
 
Buddy of mine has a Tracker junkyard just over the border in ME, if you wind up still needing stuff I can pass along his info.

I dig the build, I've considered scooping a decent Tracker to do something similar with.
 
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