Lots of good info in this thread! Nice spreadsheet even.
Common opinion seems to support keeping your Tacoma. I’ll share my opinion based on owning a 2015 Acess Cab TRD Off Road V6 4X4 with almost 50k miles, 42K of which are mine. My truck is set up with a full Icon suspension Expedition rear springs and 700# coils up front, steel bumpers and winch, 33” tires, topper. it’s heavy and I get similar mpg as you. Maybe less overall as I tow stuff pretty frequently. This is my first Tacoma and I love the truck and plan to continue to drive it daily and use it for months long camping and overlanding/trails and off road travel. I’m still spending money and time making more mods which will facilitate my planned use, including skids, exhaust and performance mods, wheels, slightly bigger tires, stronger axles and probably a slight Re-gear. So another 10k over the 12 or so I’ve spent in addition to the purchase price of $27k and change.
The ZR2 didn’t exist in 2016 when I bought my Tacoma. There wasn’t a diesel option for the ZR1’s until late 2017 either I believe. In the most recent edition of Tread magazine there’s a great write up on a super nice well built ZR2 that blew out the rear end and.....still can’t be repaired......because there’s no available rear ends or replacement parts or aftermarket....yet. All my trucks, well all but two of the 15 trucks I’ve had since I was 15 have been Chevy’s. I really love Chevrolet and GM. I probably would have bought a ZR2 if it had been available in 2016. But it wasn’t. I’d almost consider buying a ZR2 now ...if I can’t find a way to make the Tacoma seat more comfortable. And there’s the major mpg difference that has no reasonable solution...ever.
But If I can wait.... they will fix the parts availability issues, create a way to get more wheel travel with the DSSV factory shocks and get bolt on 3” lift options so we can stuff 35” tires under there without much cutting, and get some inexpensive hp and tourque increases out of the Diesel engine.
So my suggestion would be to wait, save some money up, and ask yourself if the “slightly better” things about the ZR2 are worth the money now? The other thing id do is encourage you to be totally honest with yourself about making improvements to the Chevy. Are you really ok with the ZR2 completely stock for the next two to three years? Are you really not going to spend money on making it more to your liking? Maybe the 10K difference is just the beginning?..... and also if you’re going to do some real off road driving with a new ZR2.... don’t mess up your rear end!
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I’m really good at justifying decisions which often are expensive but I’ll bet the Titan Tank guys spent over 20K in addition to the purchase price on their ZR2 and i think it’s now got welded solid rear axles and may be running in transmission limp mode from display sales area to display area... for now.
Anyway, long winded thoughts but maybe a different perspective that what’s been shared by others so far. Congratulations on the new job and thanks for your service. Best of luck with the truck decisions!