CRITICAL SAFETY ALERTS

[Iceaxe]

I've been quietly watching a few recent threads highlighting potentially dangerous things happening to our rigs that may threaten the lives of us and our loved ones. We all acknowledge these trucks are old and require maintenance, but I think we should maintain a "CRITICAL SAFETY ALERT" thread with a sticky on it.

One emerging trend, for example: steering / knuckle stud failures now documented by several of us and highlighted by the Nov/Dec 2015 TLCA Toyota Trails issue. To have these studs catastrophically fail on a mountain curve, for example, could end in a serious accident.

*** What are other key / critical safety alerts that we should document and maintain a list for to protect the drivers and their families?

 

[Iceaxe]

Here's another: wheels require torque checks regularly
Close Call Today

 

[LINUS]

IDK how much you could call it either an "issue" or just plain "not doing it right", but maybe the front brake caliper bolts that some guys have complained of?

 

[Iceaxe]

Good thought Linus... do you have links to the threads on this? I haven't read about it...

 

[jeffro109]

So far all 2/3 items have a root cause of improper torque...maybe people just need to learn that process better. I could see the knuckle studs as an easier candidate for fatigue too but proper torque helps alot.

 

[half k cruiser]

IDK how much you could call it either an "issue" or just plain "not doing it right", but maybe the front brake caliper bolts that some guys have complained of?

Was talking to @Jorgito about this just yesterday. I cannot remember what the FSM specify for ft lbs for the caliper bolts. I do know that I've torqued them to that spec before and thought it seemed a little loose for my liking. On a hunch I put my 1/2 bar on them and gave them another half turn at least. I no longer run them to FSM spec, I just crank them down until they don't go any farther. As for knuckle studs when I did my last set I cleaned them really well and added some blue threadlocker for insurance.

 

[sbman]

I would suggest that the severe duty use we put on these rigs (dozens or hundreds of miles of washboard roads, mud pits, rock climbs, etc...) would lend itself to a well developed safety checklist. With pre, post and daily checklists for items depending on their level of threat. It's what we do in aircraft where something as simple as a single loose fastener can end your life. Checkslists like this, properly developed and executed save lives. Good ones would certainly be FAQ worthy and a laminated copy stored in the rig and used regularly will make you feel both silly (who wants to walk around with a checklist) and also safe.

To start, a pre-trail daily checklist when doing off road trips might be something like:

• Front axle
  • Steering arm fasteners, check for tightness left and right
  • Tie rod ends, drag link ends, inspect for cracks and verify cotter pin in place
  • Brake lines, visual inspection for bulges and cracks
• Rear axle
  • Brake lines, visual inspection for bulges and cracks
• Drivetrain
  • Coolant level
  • Brake fluid level
  • Power steering fluid level
  • Signs of new leaks
  • Coolant hoses, check for cracks and bulges
• Tire pressures appropriate for conditions

Pre trip inspections would be more thorough and should also be performed at oil change intervals in addition to the standard routine maintenance inspections called out in the FSM.

 

[Hornd]

Make it your wives DD

 

[Iceaxe]

EXCELLENT thought / post sbman. I am totally onboard with the aviation checklist approach!

 

[1973Guppie]

more 80 series mud OCD......lol, j/k

improper torque is a major problem IMO, caliper bolts 75 lbs., I think the steering arms are 75 lbs too?, steering arms should be checked after wheeling for a day to ensure they have not loosened up, usually this is the culprit for sheared studs.

I will also say that being "in tune" with your individual truck will help you catch issues when they first arise. What I mean by this is knowing how your truck "should" feel on road so that when you feel something not right, you can check it right away.

 

[elhombre]

Here's mine for my 97:
rear torque plate 76 ft/#
slide pin bolts 65
Front caliper bolts 90 17mm
Steering arm to Knuckle 71 17mm
Diff plugs 39 24mm
Transfer case plugs 27 24mm
Oil drain plug 18 19mm
Control arm rear lower 130 22/24mm
control arms front 130 22/24mm
front disc to hub 54 17mm
steering knuckle
bearing cap 71 17mm
Rear control rod
Bolt and nut 130
Bolt 181
Front Lateral arm
Nut and bolt; bolt 127

Check Diff fluid; Oil; Power steering fluid; A/T fluid; transfer case oil
Check wheel bearings for play
Load test battery

Finally, say a little prayer that my baby will get us back from our trip under her own power! Then drive it with confidence that there was nothing else I could have checked. If it breaks down, so be it.

My friends make fun of me for always using a torque wrench................Screw them! My time and my car.

 

[2fpower]

PHH replacement -- won't cause a wreck on highway, but will strand you.

 

[jfz80]

But treadwrights will

It's an expensive hobby but if you are gonna cut corners do it wisely.

 

[jfz80]

The torque for calipers is 90 not seventy five so if we are gonna have a safety thread we should try to ensure we are putting accurate info out there

Was talking to @Jorgito about this just yesterday. I cannot remember what the FSM specify for ft lbs for the caliper bolts. I do know that I've torqued them to that spec before and thought it seemed a little loose for my liking. On a hunch I put my 1/2 bar on them and gave them another half turn at least. I no longer run them to FSM spec, I just crank them down until they don't go any farther. As for knuckle studs when I did my last set I cleaned them really well and added some blue threadlocker for insurance.

And the only problem I've seen with going past torque specs to "man tight" is I've had to deal with two calipers now the previous owner did this too and they stripped the caliper out. One just put it back with press fit loctite and moved on quietly. One redrilled and used a new bigger bolt. While a better fix than the previous it always gets me when one is a 17mm and one is a 13/64 or something stupid and not in the bag of tools.

 

[Iceaxe]

In a fit of fear of the unknown, I scampered under my rig to check the knuckle / steering bolts. Two were loose. The ones closest to the wheel are tough to get my torque wrench into...

 

[jaymar]

I would suggest that the severe duty use we put on these rigs (dozens or hundreds of miles of washboard roads, mud pits, rock climbs, etc...) would lend itself to a well developed safety checklist. With pre, post and daily checklists for items depending on their level of threat. It's what we do in aircraft where something as simple as a single loose fastener can end your life. Checkslists like this, properly developed and executed save lives. Good ones would certainly be FAQ worthy and a laminated copy stored in the rig and used regularly will make you feel both silly (who wants to walk around with a checklist) and also safe.

To start, a pre-trail daily checklist when doing off road trips might be something like:

• Front axle
  • Steering arm fasteners, check for tightness left and right
  • Tie rod ends, drag link ends, inspect for cracks and verify cotter pin in place
  • Brake lines, visual inspection for bulges and cracks
• Rear axle
  • Brake lines, visual inspection for bulges and cracks
• Drivetrain
  • Coolant level
  • Brake fluid level
  • Power steering fluid level
  • Signs of new leaks
  • Coolant hoses, check for cracks and bulges
• Tire pressures appropriate for conditions

Pre trip inspections would be more thorough and should also be performed at oil change intervals in addition to the standard routine maintenance inspections called out in the FSM.

Maybe use VDEG list as starting point and add Cruiser-specific items.

 

[Shoredreamer]

Good job Iceaxe! I was getting the ball rolling yesterday but yeah a '80 pre trip checklist' in the FAQ!

 

[mingles]

I would suggest that the severe duty use we put on these rigs (dozens or hundreds of miles of washboard roads, mud pits, rock climbs, etc...) would lend itself to a well developed safety checklist. With pre, post and daily checklists for items depending on their level of threat. It's what we do in aircraft where something as simple as a single loose fastener can end your life. Checkslists like this, properly developed and executed save lives. Good ones would certainly be FAQ worthy and a laminated copy stored in the rig and used regularly will make you feel both silly (who wants to walk around with a checklist) and also safe.

To start, a pre-trail daily checklist when doing off road trips might be something like:

• Front axle
  • Steering arm fasteners, check for tightness left and right
  • Tie rod ends, drag link ends, inspect for cracks and verify cotter pin in place
  • Brake lines, visual inspection for bulges and cracks
• Rear axle
  • Brake lines, visual inspection for bulges and cracks
• Drivetrain
  • Coolant level
  • Brake fluid level
  • Power steering fluid level
  • Signs of new leaks
  • Coolant hoses, check for cracks and bulges
• Tire pressures appropriate for conditions

Pre trip inspections would be more thorough and should also be performed at oil change intervals in addition to the standard routine maintenance inspections called out in the FSM.

I like the check list and think that keeping it as a regular routine is the key to keeping ahead of mechanical failures. I had to laugh though as most pre-trip safety checklists would actually call out looking for ANY leaks. We just need to look for NEW ones .

 

[Iceaxe]

I think a checklist is of course a terrific idea, but in that list, we should highlight the "don't ever miss this or you could have a serious, life-threatening accident" items with an asterisk....

Not trying to be a weenie here, but trying to be safe for all of us.

 

[duggy]

Mud Over-Thinking Syndrome (M.O.T.S) will take over and everything on that checklist will be marked with an asterisk.