Maintaince work prior to 30-40K world trip (1 Viewer)

Joined
Apr 15, 2003
Messages
776
Location
Ireland; USA (WA,CO, CA, CT), Scotland, London
Starting a 30-40K wee detour back to Ireland (from Seattle) in Sept that will take us up to Alaska back around down west coast - likely OR/CA/UT/CO/NM/TX into Mexico, thru Central/South America, across to Africa (route TBD), up into Europe and then across UK to Ireland and home (after many yrs in US)

Have a local fabricator/welder helping out on trailer etc. (just moved ebrake for me) with I'll be doing some work, Seattle TorFab expertise and likely some more helpers (Colorado) along the way.

Looking for some eyeballs on my list below to see if I'm missing anything. Don't expect to get it all done but at least major items that would be problematic along the way. Broken out into mechanical, electrical, fabrication, trailer and stuff to buy $.
Will have some postings on Expedition Portal but specific 80 work over here. Will post up trailer work as well (unless acquire something better)



MECHANICAL:
(T) - new hose for bottom tranmission cooler + spring pressure grip wire to hold
(T) - replace seat belts all 4 in front (no tension). Re-tension?
(T) - valve clearance check/redo - skims
(T) - small leak at oil sensor - near oil pan - needs rethreading M6x1.5mm on lower right - 4ft/lbs
(T) - check/replace tie-end rods
(T) - front birf repack/replace, new bearing/seals, grease.
(T) - check/repack grease/check bearings on rear axle
- reflush all oils (engine -10w40 sync/Rotella, tranny, tx case, brake, p/s)
- new sparks, cap, distr (add plug for water/air vent)
- fix/replace door lock rear/PS
- fix/upgrade windows that are slow
- replace all rubber grommets, axles, sway-bars etc.
$ - new shocks, steering dampner
$ - new springs (Slee, TJM prog, Js heavy)
$ - new air filter (washable)
$ - new fuel filter
- new PVC/clean-out
- redo starter contacts (have kit)
(T) - change all oils (10w40 sync/Rotella), tx fluid, brake, tranmission
- flush/replace radiator fluid (green)
- brake bleed + LSPV
(T) - replace bad u-joint on rear prop shaft
$- new p/s cooler fin (larger) at front (for winching as hydralic) - need protective plate?
https://forum.ih8mud.com/threads/power-steering-cooler-unexpected-upgrade.812280/#post-9280085
https://forum.ih8mud.com/threads/wh...-80-this-weekend.586191/page-306#post-9225807
http://derale.com/products/coolers/...opper-aluminum-transmission-cooler-kit-detail
Part Number 13264, 2 Pass 15" Heat Sink Transmission Cooler Kit
$- new brake pads FRONTs (RR ok)
(T) - check/replace rotors (FT + RR) - have readings Rear (one 'side'=5.76mm, fronts=103mm) likely need new Rears, FR ok
$- new struts for FR hood, RR tailgate
$(R) re-gearing 4.56/4.88 (Nitro/Gear- Carl)
$(T) - replace tensioner bearing (check with Robbie)
$(T) - new bearing for rear wheel swing out (droops)
LM29710 - Bearing race, LM29749 - Bearing, LM67010 - Bearing Race, LM67048 - Bearing, SL-175 - Seal, SW-750 - Washer, SN-750 - Nut, SCP103 - Cotter Pin
- check calipers + bolts
- check under knuckle bolts
(T) - re-adjust RR brake shoes (hand-brake) - get new shoes (see list for larger shoes)
$- sync winch rope
- shower water heater/piping (Ben)
(T) - fit rear air bags
(T) - fix roof PS mirror shade (magnet or replace with Tundra) - cracked/drops
- new paint job / magnetic - decals
- new windscreen + OEM rubber around
- sun visors extns
- foam seal above rad to bonnet to help with cooler air on fan
- longer range fuel tank
SOR do OEM sub-tank 50L = 13 US g too small - need approx 25g http://www.sor.com/cat250.sor
expensive MAn-a-fre 24g https://forum.ih8mud.com/80-series-tech/104791-man-fre-24-gallon-auxilliary-tank.html
dual neck fillers (new ) $350 https://forum.ih8mud.com/sale-parts/582889-brand-new-dual-filler-necks-80-series.html
(T) - put in FR part-time hubs (have parts)
- check ignition timing
- get manuals scanned and put into pc -- see mud etc.
(T) - plastic cover for bell-housing
(T) - 3 * plastic cover under truck at rear (bumper) DS
(B) - derust (rear axle, part of front, small parts chassis, where sliders connect, rear around axle) and 'chassis' paint sections
respray waxoil underneath
(B?) - take off sliders, derust, repaint (chassis hammer heavy), (replumb for air), put back on
- replace rubber on doors, windows, hinges etc. and window seals, weatherstripping $
- new headers, y-pipe, cat*2, exhaust, muffler, resonator + hangers ALL Stainless
$ - 2 OEM wheels (or use steelies from Simex)
- run wire lines from FR bumper to top of roof rack
- put in PT Aisin hubs FR


ELECTRICAL
$ - 2nd battery tray, bottle relocate, or two 12v in current location
- wiring for 2nd battery from engine to 'wiring hub' (DONE - heavy on DS, lighter on PS)
- wiring 'hub' with relays (DONE rear of PS FR seat with fusebox)
$ - dual battery controller, solenoid with 'control' in dash
- cover for fusebox
- kill switch for starter
- good GND for roof/rear, run wires up by snorkel
$ - lightbar on front bumper
$ - 4-8 LED lights around each side of roof rack (for camping)
$ - lights on front bumper (RIGID Leds)
- car-puter
- upgrade headlight harness wiring
- redo speakers on doors
- make small tweeter (under steering wheel) spkr powered from CB/Ham
- CB radio + rear aetenna (DONE)
$ - ham hand-held and Yaesu FT-857 Delta (2M & 440 - one arial and HD on 2nd aerial) + aetenna
$ - new radio aerial (fixed/bendy?) to replace broken aerial
- additional CB aerial on front ?
$ - hand-held CB/Ham
$ - 5 * hand-held walkie-talkies
$ - 12v, USB connectors + wiring on PS doors
$ - 12v and 110v waterproof outlets on outside (FR/RR bumpers)
$ - 12v and 110v connections are rear panel (fridge - anderson connection)
$ - Hella (bendy-flex) pull down (led) reading lights from roof
- bigger wire to rear tractor light - + add in extn wiring so move around able. see Kaymar extendable one
- lights under hood
$ - upgrade generator to higher output
- finish elect work, fuses, fridge outlets, 12v outlets both in and outside waterproofs front/rear, +cover, reading lights from roof etc.
- wire lights at under rear hood + stronger (LED strip) and put one into plastic (top right area space)
- new switches + panel at bottom of console and switches in new custom console
- put in CDL
- replace (D) light on console
- new dimmer switch for "high Beam" + night driving
$ - upgrade wiring for trailer (7/9 pin)
$ - wiring/relays/switches for new lighting FR+RR (bumpers + roof etc.)
- aetenna wire for WiFi etc. on roof + wiring (+ for Ham/bird tracking + gps + satelittle)
- wiring for (detachable) roof solar panels
$ - upgrade radio/cassette/cd/mp3/dvd/video/
$ - wireless reverse camera on truck + on trailer
- plug converters for usb, phones, electronics, laptops, cameras etc.. with multi-prong connections + holding area
$- shower/water heater
$- elec braker controller for trailer



FABRICATION
fix leak at y-pipe throws P0420 (maybe header area) or replace/new cat*2, exhaust, muffler, resonator + hangers ALL Stainless
new/used resonator to quiten exhaust
(B) move e-brake from DS seat position to under dash (DONE)
(B) design/fabricate custom console with safe (ditch existing one) + inverter, cupholders, map, Ram mount, USBs, 12v, 120v, A/C
- mount for GPS/Garmin on dash and swing-out (RAM?) holder (from custom console?) for iPad/tablet/notebook
(B)- hi-lift jack points on bumpers and sliders
(B)- welding work to "extend" sliders with pull out 'steps' when accessing roof. Also flip out for rear wheel steps
additional protection from front along sides (ARB) and rear quarter panel/nr lights wrap-around and steps
also from middle doors to back, possibly to roof (like Ezi-Awn)
(B)- mod existing (SS) roof rack : flip-up available from sunroof, mount for shovel/axe, locks on all/quick rls, allow for RTT at side i,e, fold, lock/swing for jerry cans
(B)- stone guard for bottom of rear shocks
$ - transfer-case skid plate
- put back in skid plate (need weld "nuts" points)
- custom drawers for rear with cargo barrier (IN PROGRESS TruckVault)
- water holder under truck + pump (under DS) ?
(T) security "rack" behind middle seats bolted to hand-grabs and floor (needed for RORO shipping).
with foldable/lockable 'hatch' for easy access.
- new seat belt for middle seat (shoulder) with routing via cargo barrier
(B) - add-on door/hinge/lockable for cargo barrier
(B) - mechanism for rear swingout so can "lock" the rear of the truck
(B) - drill/tap slider bars for air compressor
(B) - steps on rear wheel carrier for roof access (FrontRunner has these)
(B) - fabricate attachment for (alu) existing roof ladder
(B) - guard for rear shocks
.. Locks (wood) for the rear sliding windows, common in Land Cruisers, are essential as these are SUPER easy to open from the outside.
(B)- protection plate for p/s cooler ?
(B)- design folding/custom firepit/bbq grill mesh (attaches to rear wheel)
- ned tabs for wire lines from FR bumper to top of roof rack
- bracket/fittingss for compressor in engine bay
- bracket/fittingss for charcoal canister in engine bay
- Rear Bumper cut-outs/fabrication/fittings
7-pin connector on RR bummper for trailer connection (is this UK/IRL/EU compatable)
110v waterproof plugins on FR/RR
air hose connectors FR/RR bumpers
LPG fill-up connector
water hose connector (hot water)
hi-lift jack points
lights IN RR bumper (turn, brake, fog)
- Front bumper cut-outs/fabrication/fittings
110v waterproof plugins on FR/RR
air hose connectors FR/RR bumpers
water hose connector (hot water)
hi-lift jack points
lights IN FR bumper (side angle -driving switchbacks, DRL, fog)
- move existing wheel to R (will need lights in bumper) and add 2nd new swing dual carrier + jerry cans holder
- LR fuel tank + funnel + pump + switches + return (or put on under trailer and transfer)


TRAILER: (B)
- new braked axle (76" tracking) on 16" (6 on 5.5)
- level trailer to same as truck (both 'loaded' and same tires) -- re-weld tongue?
- add new leaf to springs (as too soft)
- extend tongue + possible additional space for (recovery) box
- add front+rear stabilizer legs when de-attached
- fibreglass/rubber 'mat' (see Aussie) for front-end of trailer with flip-up to stop stones
- fibreglass/heavy vinyl that attaches to rear of truck and 4 sides to front of trailer to act as a slipstream (Janicki)
- new (light- fiberglass?) hinged lid on top (dual - either side) with powered struts
- design struts (around) lid (bolted to trailer sides) for RTT (with raise/wind up 'legs' for height adjustment)
- wiring for lights, xtra battery + recharge from truck
- add-in powered water pump + plumbing 4 taps/shower
- connections from hot water system on truck or run own + shower connections/hoses
- better protection for water tank + hosing
- rear winch ?
- metal lockable box on front
- ensure with tongue (+box) rear wheel carrier on 80 will swing all way around
- dust and water seals on rear trailer lid and new cover lid
- cargoglide pull out at back
- spare wheel at front
- fuel tank underneath on back with 'fill-up' (pump/hose) into Landcruiser
- respray to match color of 80
- respray waxoil underneath
- signs/wrap/stickers to match truck logos
- test/adjust elec braker controller



NEED/BUY
$ - fridge pull/drop out slide
$ - two RTTs, one annex, mosquito netting
$ - awning
$ - fridge 63qt
$ - better compressor - put in engine bay, with hose connectors to FR/RR bumper + feed/plumbing to sliders
$- shower/water heater
$ - water filtering systems
$ - water pump
socket set (Snap-on) + deep sockets (thin wall) MM incl v.small sizes (in 1/2s as well)
bearing sockets - FR and RR
ease-out tools/socket set
bendy wrenches like Milans
wrench set + small stubby ones
snap ring pliers
onboard welder + small mask ?
$ sync winch rope + extn
$ lightforce lights ?
LPG - tanks + protection, wiring, looms, pipes, ecu, direct into injectors + diesel drip
$ tires- 255/85/R16 BFG MT KM2 * 8
... dog warning sign in the windows plus a dog that growls and barks inside the truck (electronic)
tailgate WagonGear lid (rubber) http://wagongear.com/shop/80-series-tailgate-lid/
extend front roof rack so shade on truck from sun
"drone" helicopter (recharge batteries off car) that can take off from roof and follow (gps/tracker) to truck and show whats ahead (webcam) + show truck below via high-def webcam + transmitter/receiver (video)
wifi gear - aetennas etc. http://www.camperforum.nl/viewtopic.php?p=477723
$ - recovery stuff (gloves, U bolts, tree protector, kenetic jump/pull rope,
$ - jerry cans, water cans
$ - sand/bridging ladders, maxi-traks
- "drone" helicopter (recharge batteries off car) that can take off from roof and follow (gps/tracker) to truck and show whats ahead (webcam) + show truck below via high-def webcam + transmitter/receiver (video)
$ - hot water/shower system
$ - new seat covers
$ - replace seat cushions (+custom fit for seat/back) for FR and middle + re-do leather
$ - foam/material for new custom console/armrest
$- elec braker controller for trailer
 
Joined
Mar 3, 2014
Messages
686
Location
Miami
This sounds like a fun trip. Good luck and have fun!

Edit: You should start a "trip thread" and post a photo a day from your trip.
 
Last edited:
Joined
Mar 6, 2009
Messages
1,820
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Between pixels
Sounds like an awesome adventure. Best of luck. Here's my .02 cents:

Mechanical

- have starter rebuilt or replaced vs. just changing contacts
- replace Y-pipe vs. welding crack
- replace O2 sensors if not replaced recently
- replace all rubber brake hoses and check condition of hard lines for signs of rust
- replace all engine coolant hoses incl PHH if not done at engine rebuild
- replace all vacuum hoses if not done at engine rebuild
- replace all u-joints vs. just one
- check and replace rubber fuel lines as req'd
- install snorkel?
- check engine fan clutch hand repair OD replace as req'd
- rebuild or replace brake calipers
-

Electrical

- replace all int/ ext bulbs (replace headlight bulbs with higher output from Candlepower)
- properly fuse all add-on electrical circuits
- get photomans kit for 150/180A larger Tundra alternator
- make schematics of all electrical add-ons as this will be crucial for trouble shooting on the road.


Fabrication

- install compressed air tank under vehicle

Need/ Buy

- instead of having to carry many water jerry cans, you might want to look into the "Live saver" filtering jerry can that can make almost any water potable but it is $$.

I love modding my vehicle (dual battery/ rear inverter, 12V receps, Hella map light, engine mounted air comp, etc.) but there is something to be said for the KISS principle. More "stuff" is just more points for failure. I always think of the German couple that drove a stk G-Wagon some 500K miles around the world with almost no mech issues and no fancy overland equipment.
 

Mattnatti

See a Doctor and get rid of it.
Joined
Nov 11, 2011
Messages
686
Location
sOHIO
Sounds like a lot of work between now and September. Good luck on the journey and congrats on choosing a what will be satisfying and hopefully uneventful ( truck wise ) trip home.
 
Joined
Jan 16, 2010
Messages
1,312
Location
Rocky Mountains, Canada
Hey theLal -
Can't wait to follow your family's travels. In hindsight, being weight conscious was the single most critical prep. Few suggestions regarding your 80's weight, FWIW:
- tires will wear faster, brake pads and your whole driveline. Suggest bringing extra pads, beefing up your tranny (wholesale auto) and replacing all rubber bushings with new OEM.
- if you add a lift, do not use castor bushings. Or stay stock height with the roof rack.
- ditch the 255's for 285's. I couldn't find 255's anywhere.
- axle studs will need beefing up.
- add gusset plate to frame behind steering box.
- no need for welder IMHO.
 
Last edited:

UnderDawg

Wannabe welder
Joined
Feb 17, 2013
Messages
733
Holy sheep shi*T Batman!!! You got some sponsors or just deep pockets? Also do you need a new favorite nephew? I can help you with the second question.
 
Joined
Apr 15, 2003
Messages
776
Location
Ireland; USA (WA,CO, CA, CT), Scotland, London
yes- did see about the faulty fuses - kinda scary. Will be checking all of mine

Not planning on Baja as need to make some miles but if had time would do so. Most travellers find it great

Canman good info. Do have a snorkel.

Will miss Overland Expo - timing wise

Shred -- do agree on the 'keep it light'. All the overlanders that have stayed with us - thats one of the their rules. Will be keeping that in mind as I likely will have 3-5 "packing" attempts before I'm done. With 3 kids most of 'luggage' with be trailer based but again want to keep it as light as possible. No doubt I'll be chucking stuff away along the journey that I "thought" I needed.
Do have a water tank under the trailer but will need to hook up some filtration system. The jerry-can all in one looks like a good idea.
Can you explain these two
- axle studs will need beefing up.
- add gusset plate to frame behind steering box

Working with some sponsors but mostly savings, some work along the way, some 'parts' accumulation along the way (wish I had done more). However once you leave your home/house all those expenses vanish -- most overlanders try and stay within a $75/day all inclusive budget while on the road (excluding shipping etc.)
 
Joined
May 16, 2008
Messages
734
Location
Bend, Oregon
Starting a 30-40K wee detour back to Ireland (from Seattle) in Sept that will take us up to Alaska back around down west coast - likely OR/CA/UT/CO/NM/TX into Mexico, thru Central/South America, across to Africa (route TBD), up into Europe and then across UK to Ireland and home (after many yrs in US)


FABRICATION
fix leak at y-pipe throws P0420 (maybe header area) or replace/new cat*2, exhaust, muffler, resonator + hangers ALL Stainless
new/used resonator to quiten exhaust

Looks like an awesome trip you have planned. I'm hoping to ship my cruiser down to SA this fall and spend half a year down there so we might cross paths.

I have a used resonator that I pulled off my exhaust when I replaced the whole thing. Already cut down, yours for free if you want it and would use it(would just have to figure out how to get it there). :cheers:

Corey
 
Joined
Apr 15, 2003
Messages
776
Location
Ireland; USA (WA,CO, CA, CT), Scotland, London
Corey - sounds good. Exhaust (2" or maybe 2.5) at the moment is ok but with 30-40k miles ahead decrease cabin noise seems like a good idea right now. I've not put insulation on roof and methinks I should (quietcrap stuff and 'noise' insulation + 'heat' insulation - hot sun africa etc.. really need to do a white paint job at some stage along the way)
 
Joined
Apr 15, 2003
Messages
776
Location
Ireland; USA (WA,CO, CA, CT), Scotland, London
Cleaned up a set of birfields/cvs I've had some time ready for TorFab next week. Front axle overhaul

Added some door insulation (have all floor and body panels done for quite some time and all new wiring put in ready for custom console) to decrease noise and heat. Unlikely I'll do the roof as most folks that have done it (TreeRoot) don't think it was worth the effort.
Couldn't find whats wrong with middle/PS lock - opens ok with remote but refuses to close and have to do manually. Didn't manage to take out the motor to check it out. Forgot to take out window motor to inspect.
Will be adding 12v/USB power to both middle doors.
birfs_1_email.jpg door_1_email.jpg door_stuff_email.jpg door_2_email.jpg
 
Joined
Apr 15, 2003
Messages
776
Location
Ireland; USA (WA,CO, CA, CT), Scotland, London
Got Edgestar 63qt fridge (small dent at bottom via scratch-n-dent deals). Now need to get some sort of slider rails organized (anyone got some DIY pointers)
edgestar_box_open_email.jpg

Did some de-rusting on rear axle (front all looks fine). More to go and plan on WaxOil the undercarriage before I leave

undercarriage_1_email.jpg undercarriage_2_email.jpg

Got a bunch of 15w 30degree LED lights ready to go on roof rack & trailer. Need to find DRL and/or "real" fog lights for rectangle cutout on ARB front bumper (small 5.4x1.5 in). Anyone found anything that worked.
May do small light bar on bat above winch and maybe two of those leds for 'side' view (switchbacks) on bumper

ledsx4_email.jpg
 

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