Recommended Defender 90 TD5 Overland Spares
 

Hi, I have a 2001 D90 TD5 I am prepping for overlanding around Europe, Africa and ultimately World wide.
Looking for advice on what spares to carry. But before the list materialises let me first say I have limited mechanical experience. Changed oil, water, coolant, filters etc in the past but that just about sums it up. I have a mate runs a garage who is going to help me out to complete some D90 specific training i.e. on my own landy but that is not for a while. Also appreciate any experiences of specific failures.
Thanks bier

Fill a box with bits 'n bobs, tiewraps, elecrical wire, fuses, etc.
Large bits: shocks, leafsprings, startermotor.

But in the end, the part you need is the part you didn't bring...:taz:

You'll certainly have gone wrong big style if you need the spare leafsprings on a 90 :cool4:
Take at least a sump worth of oil, ditto with axles.

I am a firm believer in changing old parts out before the trip, start out with new ancilleries and consumables on the vehicle and carry a minuimum of spares - especially on a 90, where space is limited.

If you load the vehicle down with spares, you put more stress on the engine, drivetrain and chassis, which equates to more chance of something breaking, as mentioned, you probably wont have exactly the spare you need anyway!

with a 01 Defender, id probably replace the radiator/mounts as a matter of course for going to Africa, it will probably be corroded internally - which will affect its cooling ability and the washboard/corrogations give it them a hard time, often causing leaks in older parts like that.
Also have a good look at the alternator and PAS pump, any whining from the alternator bearings - swop it out.

Id be more inclined to carry a spare ECU for the Td5 than anything else, change the fuel lift pump and carry a spare, maybe carry a spare rear and front shock too, take engine oil, gearbox and axle oil as mentioned, spare oil filters and fuel filters (lots) and change fuel filters often in Africa

This can also happen on a Td5, so check the harness is good before you set out:

www.discovery2.co.uk / Workshop /Injector Harness

Dont take too much crap, pack light!

A spare ECU would be handy, but they're pretty reliable.

Invest in a nanocom. older or newer ones are fine, and make fault finding much easier, and you can also change lots of settings on the engine/ECU. and test injectors, pump, MAF etc.

Other parts to carry, i'd have a MAF (Mass Air Flow meter), clips on to the air box where the turbo pipe goes. if this MAF goes duff, the engine will still run, but be a bit flat.

and a CPS, Crank Position Sensor, sits on the bellhousing under the air box. this is the only sensor that will stop the engine if it goes dead. costs about £40, and is held in with one 10mm bolt and a plug (and needs no ECU setting/NASA computer to install it, same for the MAF)

In fact, contrary to popular misconseption, the only things you need a nanocom/computer for, if changed, are the injectors, alarm 10AS unit and the main ECU.

and the engine will still run with the wrong injector cdde in, albiet not quite as efficient as normal.

Before you leave, as said above, check for oil in the ECU loom. and change the injector harness (about £50 and 20 minutes work)

Ditto on the MAF sensor, Crank position sensor, possibly a fuel pump (but they're bulky, and a bitch to change on a 90 if you've got a towbar on that hasn't been removed lately!)
I would say DON'T carry huge amounts of oil - the world relies on diesel powered vehicles. You can usually find what you need! A top up bottle of engine oil and clutch fluid should do, but a complete fluid change before you go would not be a bad idea.
Pair of wheel bearings and a hub seal.
As mentioned, change the injector harness, and check the ecu plugs for oil. If it's dry, the ecu should stay reliable unless you drown it!
Take a clutch master and slave cylinder (TRW/genuine Land Rover ONLY!)
Radiator and intercooler inspection/replacement as they're prone to leaks between the plastic and aluminium, and the intercooler fins can expand and split with age.
Check the fuel pressure regulator isn't leaking onto the starter motor. If it is, replace it AND the starter. (Beware the wet look on the starter can also be oil leaking from the rear camshaft bung - this is not such an issue, it's dieselwash that destroys the starter.)
Remember DHL will ship to most countries!
Enjoy the trip and don't get too hung up on what to take. If you've got food, water and shelter, you're already onto a winner!
Simon.

I disagree with some of the above, but....... you really need to be more specific about where you are going, for how long, what kind of travel you will do (cruising around enjoying yourself or really heading to remote places alone) and most importantly, what kind of driver you are?

Then its easier to offer more specific advice.

My advice is to take as many spares as you can, when you have a problem having a right part is half of the problem solved already.

For example take every seal as they are small and light. Take a full change of oil for everything, or at least extra motor oil as it can go in the gearbox in an emergency, and so forth...

I don't want to upset anyone on here, but I really don't understand the obsession (sorry, probably too strong a word...) with carrying what amounts to large quantities of oil. I have run trucks and 4x4s in Asia, south America and central Africa for 15 years, and we don't bring them back to the UK to fill jerrycans of oil for servicing. Land Rover axles will run on virtually any gear oil with an EP (extreme pressure) rating, as will the transfer box. The gearbox on a TD5 will be happy enough on ATF D2 auto transmission fluid, (although the later spec MTF94 is smoother on the change) These and Dot 4 clutch/brake fluid I have found all over the world. Alright, 5w30 semisynth for the engine is a bit more rare, so if you're planning more than 6000 miles in the bush without going through a big city you might struggle to find it, but just head for the nearest UN mission in Somalia and you'll probably be able to wangle some!
Just leaf through some of the posts further north on this forum and think what a biker can/needs to carry!
My twopenceworth!
Simon.

there is some cabling that runs through the rocker. As the seal wears oil weeps along it, eventually disabling the engine. Can't remember the specifics but your mate will know if he is familiar with TD5s. Went on my mums TD5 disco when they were down visiting. No warning, just wouldn't start. catastrophic if your in the middle of nowhere. THH a TD5 would not be my choice of expedition motor. If your set on a landie I would go for a reall good 300Tdi, but I appreciate changing may not be an option.


PS
just read through the above, it's the injector harness!!! get it changed and take a spare, it's not an expensive fix. I tend to fit new parts and take the old ones with me. That way, I know they will fit!! But, as suggested above, it's a balance of taking enough vs taking too much. More important is probably your bodging kit. radweld, block repair, nuts and bolts etc etc

Also as above. most parts can be bought in any large town or couriered in, so I tend to try and carry parts that would help me reach that town in the event of failure.

The point of carrying a sump/axle worth of oil is not necessarily servicing, more in case you lose most of it before you can use the epoxy metal. I had the front prop come loose and beat hell out of the oil filter on a landcruiser in the Kalahari which could have meant walking out.

there are also counterfeit oils knocking around in eastern Europe in branded packaging

tow a Landcruiser behind you:clap:

calm down dear, it's a joke, A JOKE!!

sorry, too much time spent on boring admin today!!:thumbup1:

whats the joke ? Ive had to tow quite a few Landcruisers :cool4:

+1 :rofl:

Happy trails,

Gee