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My 03 is getting close to going back into service. After some allotted time to work out bugs/issues I'm going to be taking it on several long road trips w both on/and off road parts. I want to put together a smart tool list and get some ideas for what to brings as spares/supplies
The meat of what I've done (and doing) so far:
Head gaskets w full valve job/machined heads
New lifters
Water pump
Oil pumpTiming chain
Front seal
Rear main seal/ crucifix seals
Oil pan gasket
Plugs/wires4 O2 sensors
All hoses (w Extinct's in line mod)
New radiatorNew belt
Ultragauge
New pads and rotors all around
All the bearings check out good
Terrafirma Lift/shocks
Front driveshaft
rear coupler
Exhaust gaskets
Checked/cleaned and rewrapped the entire engine harness
4 new tires
A fully rebuilt 1.4 low ratio CDL Case
All fluids changed
Diffs now have metal fill plugs
Terrafirma diff guards front and rear
New OEM steering parts done just before I bought it
New power steering pump
All power steering lines
I am going to carry a spare CPS because if that does I'm dead in the water. A small amount of spare fluids. Hose repair kit. Tire repair kit.
The tools is where I always over pack. I'm trying not to have a boatload of extra weight in spares/tools. But I think taking 20 year old vehicle on a 3000 mile road trip and doing some heavy off roading...means you take tools. I'd like to hear what you pack.
Last edited by Shiftonthefly1; Apr 14, 2021 at 11:00 PM.
Spare fuses, CPS, spare spark plug wire or wires, hose clamps, zip ties couple of spare relays, hidden spare key (you'd be surprised what can happen to your main set of keys miles n miles away from no where....), spare misc bulbs (H7 for sure on an 03-04 facelift D2), then just the usual spare fluids, water, some work gloves, and a small moving blanket to lay on in case you have to get underneath it. I also personally always carry a spare alternator if I'm going way way out in the boonies as without an alternator you are on borrowed time once the battery runs down.
In addition to the conventional tools, PB Blaster, funnels, multimeter, manual fluid pump, duct/gaffers tape, electrical tape, wire & alligator clips, 36mm fan clutch wrench, coil pack, a length of fuel hose and assorted band clamps. Gear pull and ball joint splitter if you want to get really nuts.
Spare fuses, CPS, spare spark plug wire or wires, hose clamps, zip ties couple of spare relays, hidden spare key (you'd be surprised what can happen to your main set of keys miles n miles away from no where....), spare misc bulbs (H7 for sure on an 03-04 facelift D2), then just the usual spare fluids, water, some work gloves, and a small moving blanket to lay on in case you have to get underneath it. I also personally always carry a spare alternator if I'm going way way out in the boonies as without an alternator you are on borrowed time once the battery runs down.
Would you carry a spare alternator, if you had a spare external battery and solar charging system, such as the Yeti 1900?
I haven't thought of carrying a spare alternator before, but I carry solar panels to help charge.
Depending on the type of trip I'll sometimes bring along spare driveshafts (rear has a good flex coupler), jack stands, floor jack (have hi-lift but those things scare the crap out of me so it's a last resort), and a lot of spare fluids on top of the usual hand tools.
D2 Alternators are pretty robust especially vs a D1, but I've seen plenty of Bosch/Valeo Alternators suddenly bite the dust, and it just depends how far out in the middle of nowhere you are. I personally always carry one or at least a new regulator with new brushes.
I've driven a D1 with a dead alternator at night and I made it 35 miles home safely, but when I rolled into my driveway my Scangauge II showed the battery at 8.2v and it died about 10ft after that. I was 2 merit badges away from an Eagle Scout so I still live by the "Be Prepared" motto lol.
Last year I hit a rock on a bad trail with my Xterra and I tore the diff cover just enough to let all the oil drain out in about a 100 miles of off road driving. We wound up walking 19 miles before being picked up by strangers in the dark. Riding in the back of a pick up truck freezing. Although a funny adventure now, it ruined the trip and I'd like to try and avoid any deal breaking events.
Off road Parts/Supplies/Tools
