Vehicle Recovery Gear List

Global Supply Chain and Support Network

First let us introduce our Adventure Truck, it is a Mitsubishi FUSO FG Canter. This truck has been manufactured since 1963 and is now in its 8th generation of design. It is marketed, sold and supported in 150 countries around the world with production factories in Japan, India and Portugal. And while there are different variants of the truck are produced, the 4P10 diesel power-plant is considered a “world-engine”; an engine that Mitsubishi have been producing since 2009. In most parts of the world this engine is paired with a 5 speed manual transmission. We have the North American variant of the engine, which has the exotic 6 speed Duonic transmission, a more complex emission treatment system, and more power from the addition of a twin turbo. So, while in theory it is a truck with a world engine and we will be able to find mechanics around the globe to work on her, in practice it is a little more complex.

The heritage of our truck along with the support available globally is however a huge positive and has a big influence on the spare parts and tools we carry. Knowing we can likely source parts locally wherever we are in the world, means we can keep the spare parts and special service tools for the truck to an absolute minimum. What can’t be sourced locally we can have shipped to us. But probably even more important, we will likely be able to find a mechanic locally with knowledge of our truck including special service tools and the FUSO diagnostic equipment.

Travel Style

The next biggest consideration influencing our gear list is our travel style. We travel for extended periods of time, by ourselves, often to remote places, making up our travel plans as we go and trying very hard not to make too many commitments, especially date based commitments. This is just how we like to travel.

Truck failures often disrupt travel plans while repairs are performed. Disruptions are minimized when less travel plans exist. For example, we can sit in a campground and wait to have the required parts shipped in, or maybe we head in a different direction than originally planned and to bigger town to have parts shipped there.

Having no commitments is obviously not always possible, ships sail on a schedule, visas and temporary import permits expire, vehicle maintenance has to be performed etc, but we try to minimize any such commitments. Our plan-as-we-go style of travel allows us to tolerate the disruption and inconvenience of failures with more ease. This has the added advantage that allows us to skew towards taking less spare parts and tools than others with more time constraints might take.

Our Skill Level

We have very little mechanical skills, and we are not likely to become mechanical experts anytime soon. While we can perform basic maintenance activities and common-sense in-field troubleshooting, we will not be doing any major in-field repairs, lime rebuilding the rear diff on the side of the road. Our limited skills means we are somewhat forced to rely on others to help us make repairs. We are also going to rely on their supply chain for spare parts and their workshops for special service tools. No need to carry the spare parts and special service tools to rebuild the rear diff when we have no idea how to rebuild a rear diff.

Unit of Failure

Failed parts can be either be replaced with working parts or they can be repaired to be made to work again, at least for a while. The choice to replace or repair is often determined by the strength of the local supply chain. Replacement is preferred and is standard practice in developed countries with a strong supply chain and high cost of labour. But in many cases a local repair, especially in less developed countries, can allow travel to continue creating more time and logistic options to get the correct replacement part. For example, in Laos the Double Cardan joint on our Land Rover front prop shaft severely failed, but was repaired with grease in a few hours by a local repair shop with this repair lasted 3,500 kms. We eventually replaced the failed bearings a month later in China (from parts supplied out of Australia). Local mechanics can be very creative.

Vehicle Extraction Gear

Extraction gear is a bit of a special case. While failures can last days or weeks, getting stuck is typically measured in hours. And if we are really stuck, then we are going to need assistance from others, which we are not afraid to do. Just like we are happy to help others when we can and it makes sense to do so. When Overlanding, the truck is our home and we do not really want to break our home. Our vehicle is very capable in rough terrain, but we do not need to go looking for trouble. Instead we keep the vehicles capabilities in reserve to get us out of trouble. Therefore when Overlanding, we are more conservative with where we go. In contrast, if we are 4-wheeling the back-roads with friends in the United States, then we are much more adventurous and take much more extraction gear.

These considerations combine making it easy to justify taking less extraction gear. Consequentially, the amount of extraction gear taken is replaced with taking high quality gear. Extraction gear is also less dependent on the specifics of our truck.

Recovery Equipment includes three categories

• Spare Parts
• Tools
• Extraction Gear

The actual gear list is specific to our Earthcruiser, and for our recovery and not the recovery of others.

Spare Parts are those parts which we carry with us and allows a more convenient and rapid replacement should the original part fail. They include consumables like filters and fluids.

Tools that are used to replace or repair parts of the truck. They include special service tools which might be unique to our FUSO truck or the house.

Extraction Gear is for getting the vehicle unstuck. While extraction gear is really just a special form of tools, nonetheless it has its own category.

A special thanks to Randy (EC #37) for his help in putting this gear list together.

Vehicle Extraction Gear

Extraction gear is a bit of a special case. While failures can last days or weeks, getting stuck is typically measured in hours. And if we are really stuck, then we are going to need assistance from others, which we are not afraid to do. Just like we are happy to help others when we can and it makes sense to do so.

When Overlanding, the truck is our home and we do not really want to break our home. Our vehicle is high clearance 4-wheel drive and very capable in rough terrain, but while overlanding we do not need to go looking for trouble. Instead we keep the vehicles capabilities in reserve to get us out of trouble. We are more conservative with where we go. In contrast, if we are 4-wheeling the back-roads with friends in the United States, then we are much more adventurous and take much more extraction gear.

These considerations combine making it easy to justify taking less extraction gear. Consequentially, the amount of extraction gear taken is replaced with taking high quality gear. Extraction gear is also less dependent on the specifics of our truck. The following is what we carry as part of extended Overland travel.

Overlanding List

• On our front bumper is a 16,500 lbs WARN winch (with 3/8” x 100’ synthetic rope from Spydura rated to 17,600 lbs and Epic winch hook rated to 18,000 lbs with beverage opener).
• Winch line extension (from Blue Ridge Overland, 3/8″ by 50′, rated at 17,600 lbs MBS).
• 2x soft shackles (from Bubba Rope, 7/16″, rated at 45,000 lbs MBS).
• Tree saver strap (from ARB, 10′ long, rated at 26,500 lbs MBS for straight pull).
• Hitch pin to connect to rear hitch receiver to create a towing point (from factor 55, rated to 9500 lbs WWL and 50,000 lbs MBS).
• Four Maxtrax MKII Vehicle Recovery and Extraction boards. Coloured Olive Drab to match Molly. And two go-treads traction boards, which have only ever been used to level the truck while camping.
• Shovel with long handle and work gloves.
• Regulatory breakdown equipment, including two high visibility vests, a warning triangle and some roadside chemical lights. These items are also useful in avoiding overzealous police officers trying to exact money from us.
• One set of snow chains. We carried snow chains in our previous Overland vehicle, and thought we would never need to use them, until we did. Same for Molly, we wouldn’t want to be driving on a snowy road without knowing we had snow chains. Like the regulatory breakdown equipment, useful to carry chains for compliance reasons.

4-Wheel Driving List

The Overlanding extraction gear is only sufficient for a simple single pull recovery. With the following additional recovery gear we can setup for a double, redirected or even a triple pull. 

• All of the items on the Overlanding list plus
• Kinetic strap from ARB rated at 33,000 lbs MBS
• 2x Recovery Rings from 7P rated at 40,465 lbs MBS
• 2x 7/8″ Van Beest Screw Pin Shackle rated 85,800 lbs MBS
• 1x 20′ bridle strap from Masterpull rated at 21,500 lbs MBS straight pull (Macgyver)

Spare Parts

Molly will be stocked with a minimum of spare parts. Clearly we are planning to go to some far off places, and for sure some of these places will not have the parts, or even services, that we will need to complete a part replacement. So having some spare parts makes sense, the difficult part is trying to predict which parts might fail and thus what makes sense to have handy versus what is better left behind.

Our philosophy is to carry spare parts that are known to fail, that fail without warning, are hard or not practical to repair and are small enough to carry so they don’t take up too much valuable cargo space and payload allowance. The spare parts list has been divided into the following sections, with both critical and non-critical parts and includes the truck as well as the camper.

• Mechanical
• Rubber
• Electrical
• Sensors
• Consumables

Critical parts, are those parts, that should they fail, then Molly as a whole will also fail. Molly is critically dependent on the correct operation on these parts, and no work around is available. For example, the ECU is a critical part. Non-critical parts are the opposite, if they fail, Molly can continue with either a work around or continue in limp mode. For example, the front prop shaft is non-critical, as it can be disconnected if it has failed¹.

There is chance that some of the spare part being carried will not work when required. In some cases we pro-actively swap the current and working part with the spare, proving that the spare works and making sure we have the right tools to complete the swap and know how to do it. The original part then is added to the spares parts box.

Further research and talking to Fuso service centers and other Earthcruiser owners is needed before this list can be finalized.

Mechanical – Critical

• Some spare wheel nuts, both left and right threaded. Because they do come off even if they shouldn’t. We have added loose wheel nut indicators, and carry some spares of these as well.
• Oil drain and inspection plugs, for engine, transmission and diffs (MK666976, MK666977, ME609400, ME609401, MB001293, MB001294, ME609555, MF665007).

Mechanical – Non Critical

• The DEF Dosing unit is known to get clogged and cause the truck to go into limp mode. Apparently an easy fix, just rinse the injector with warm water. We carry a new clamp (ME556057) and Gasket (ME556058) to make this procedure easier.
• The service interval for the PVC filter replacement is 30,000 miles (48,000 kms) or every 36 months. The PVC can go bad early, so carry PVC Filter (QC000454), Shaft Seal (MK667058) and Housing O-Ring (MK667060). We also replace the PVC filter every 15,000 miles preventatively.
• House fresh water pump by Whale (FW0814). We have already had two of these fail on us, so seems reasonable to carry a spare.
• Motor to retract and deploy the house steps (Kwikee 676061). This motor has failed on us in the past.
• Drain plug for secondary fresh water tank (add specs).

Rubber – Critical

• Full Size spare wheel and tire, 20 ton hydraulic bottle jack, wheel nut wrench² and a “nut buddy” to loosen tight wheel nuts. Taking a second spare wheel or just a second tire is not going to happen, and something we have never considered seriously. If we are going places that need a second spare tire, well maybe that is not a place we want to go. Our tire size (315/75R16) is fairly standard worldwide. We also carry the ARB Speedy Seal Tire Puncture Repair Kit and have an onboard air compressor with air hose and tire inflator guage.
• Serpentine Belt and tensioners. Belt (MK667789), Belt Tensioner (MK667238), Alternator Tensioner (MK667237)
• Brake hose to wheel (MH033291). We have had one of these fail already, but that should not happen again.
• Replacement coolant and other engine hoses are not carried, but the tool bag contains repair tape.

Rubber – Non Critical

• None.

Electrical – Critical

• ECU. Yes, you heard it right, an Engine Control Unit (MK6677310). Seems like a strange choice, as ECUs just don’t fail. We purchased a second ECU, had it flashed with our VIN, the FUSO latest software and a small modification to improve engine performance when at high altitude and in parts of the the world where we can’t get ULSD diesel. We did this to allow us to run on low quality diesel, but also has the added advantage that this second ECU can also be a spare. The local FUSO dealer thought we were crazy. More on the second ECU can be found here.

Electrical – Non Critical

• A small collection of bulbs and fuses suitable for our truck. Some electrical wire, because you never know.

Sensors – Critical

• To be researched and completed

Sensors – Non Critical

• To be researched and completed

Consumables

• PM Filter Kit (KT212007). Includes air filter (ML242294), oil filter kit (QC000001) and fuel filter and o-ring (ML239124)
• Mobil Delvac LE 5W30 synthetic motor oil (API CJ-4). In countries with high sulfur content in the diesel, it is important to use engine oil with low SAPS, to further help the DPF from not getting clogged.
• The Webasto stove has a fuel filter that needs to be replaced every 12 months (1319466A). The air and water heater does not have a fuel filter.
• Seagull water purification filter (RS-1SG) which needs to be replaced yearly.

Spares Parts not Carried

If something fails beyond what we are carrying, then we will be spending a little extra time in a location where we were not planning to spend a little extra time. There are a number of items that almost made the list:-

• Brake Seal Kit (MK528490).

Basic Tools and Stuff

We have a STEP22 Pangolin tool roll filled with basic tools and a Adventure Tool Bag filled with “stuff”.

Our tool roll contains a basic tool set. Just enough to complete simple jobs and includes

• Pouch 1. A 10 piece flat-head and Phillips head screwdrivers set, terminal driver and hex driver. Set of metric Allen Keys.
• Pouch 2. Vice grips, channel lock wrench, electrical crimper, wire stripper, long nose pliers, curved long nose pliers (for PCV filter removal) and wire cutters.
• Pouch 3. Metric socket set, 1/4″ drive 4mm to 9mm sockets, 3/8″ to 1/4″ driver adaptor, 3/8″ drive 10mm to 19mm regular and 9mm to 18mm long sockets. Two 3/8″ socket drivers. Short, medium and long extension bars. Medium adjustable crescent wrench.
• Wrench roll. Metric spanners 6mm, 8mm, 10mm to 19mm, open end and closed ratchet end. Duplicates of 10, 11 and 13mm.
• End pouches. Various hex bits, drill bits and a reamer bit.

The tool bag contains the following stuff

• Electrical: electrical tape, cloth loom tape, cable ties, coloured heatshrink, spare fuses, electrical wire, crimp terminals, 12 volt soldering iron, solder, multi-meter, dc amp meter and OBDII reader.
• Plumbing: Assorted hose clamps, thread tape and Silicon self fusing repair tape.
• Grease. Mini grease gun and red n tacky grease cartridges, cans of WD40 and dry lube.
• Collection of assorted metric stainless steel bolts, washers and nuts.
• Duct tape. Ball Peen Hammer. Measuring tape. Work gloves. Torque wrench.

Specialist Tools

• Precision Instruments, 3/4″ Drive Split-beam Click Wrench – C4D600F to torque the nuts on the wheels.
• 3/8″ Drive 12mm Hex Bit Socket for the engine oil drain plug (oil pan).
• 3/8″ Drive 32mm 12point socket for the oil filter.
• Torque wrenches, first is 5 to 80 ft.lbs and the other is 50 to 250 ft.lbs.
• Need to add a snap ring or cir-clip tool for the PCV filter replacement procedure.

Manuals

We carry electronic versions of the following useful manuals.

• Owners-Manual-FUSO-2017-FE/FG
• 2017 Service Manual
• 2017 Fuso Diagnostic Codes List
• Fuso-Group-13E-Engine-Control
• Body Equipment Mounting Directives – Fuso-2017-FE/FG
• Earthcruiser Manual

Other Items

For those truly off grid adventures and for emergency only purposes, we also carry

• MSR Whisperlite International stove and small fuel bottle, just in case our main stove gives up the ghost. It can burn diesel, but prefers gasoline or white gas.
• A hand pump Katadyn water filter for water purification and some water purification tablets.
• Space Blankets that also act as ground sheets.