Thanks for all of the responses! I've been looking at a lot of the build threads and getting lots of ideas. The biggest reason I was considering the trooper was for the overall size of the vehicle. Glad to hear that the LS or SR is similarly sized. So is there a better year? I understand that starting in 2000 the trucks went unibody. Is that a detractor? Or nothing to really worry about?
I'd like to keep this for a long time and build it into a hunting/camping rig. I run a couple of bird dogs and travel with them to hunt pheasant, quail and grouse, so I need to have room for crates and stuff that's why I'm looking at larger SUV's. The reason I want an SUV rather than a truck is to keep the dust off of the dogs and gear when traveling back roads.
Keep the opinions coming.
The unibody vehicles were first sold here in the states back in 2001. The 1998-2000 Montero's are considered to be a Gen II.5. The Gen II.5 had the largest wheel openings of any Montero and it is possible to fit 35-37" tires with little effort.
1983-1991 Gen I Montero, very spartan and no safety features, but my 1991 was a blast to drive.
1992-1997 Gen II Montero. The Gen II Montero came in many different configurations but the 1994-96 SR model is the best choice because of its 215hp & 228ft lbs. DOHC 3.5L engine, 9.5" locking rear axle and 4.63 gears. The 1997 came with the detuned 3.5L SOHC 200hp engine and 4.27 gears, but retained the Gen II sheet metal. If you are Looking for a manual transmission, look for a 1995-1996 LS because they were rated at 177hp, which is 34 hp higher than the previous models. The rear locker was not offered on LS models but a rear LSD was offered on the LS model.
1998-2000 Gen II.5 Montero. The Gen II.5 Montero had the largest wheel wells of any Montero and it is possibly the most desirable because of this. It featured a 200hp & 228ft lbs. SOHC 3.5L engine, 9.5 locking rear axle and 4.27 gears. While the SOHC made 15 less hp it still made the same amount of torque as the DOHC 3.5L. The SOHC also seems to be more reliable because it does not have butterfly valves. The Gen II.5 is by far the rarest of all the Montero's. With there very unique styling and limited production numbers, they seem to demand a premium, but good deals can still be had. If you want a nice low mileage Gen II.5 expect to do a nation wide search for several months. The Gen II.5 also features driver and passenger air bags which can come in handy.
2001-2006 Gen III Montero. The Gen III Montero seems to have two basic variations. From 2001-2002 you had the 3.5L and from 2003-2006 you had the 3.8L. Many members swear by the 3.8 and say the add hp is well worth it, but the 2003-2006 was not offered with the LSD like the 2001-2002 model was. So there is a trade off. You also need to be aware that there were two automatic transmissions and two transfer cases which were used. I would look for a 5speed automatic with the select-able sportronic over the venerable 4speed automatic. I would also look for the tcase with 2wd, AWD, 4Hi, and 4Lo, but thats just me. Some like the tcase with out the AWD mode found on the XLS model because it has a shifter that directly shifts the tcase.