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What is most likely to break when off-roading?

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12K views 42 replies 24 participants last post by  Sparky of NWO  
#1 ·
What has broken on your rig when off-roading?

What have you heard from others?

What spare parts, if any do you carry when off-roading?

I'm thinking of taking my old tie-rods as trail spares (along with the tools needed to swap them out). Do tie-rods ever brake/bend on the FJ? It seems like a pretty common problem on the new Ford Bronco.
 
#24 ·
Yes, the first thing I bent on my first trip to a park. I quickly upgraded to HD links. Also, skid plates offer peace of mind.
 
#11 ·
Inner and outer tie rod, belt, hoses, cv axle when going way out, and probably most likely to fail, a tire ;)
 
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#13 ·
2nd vote for cv joints.... swapping out a complete axle can be done in 20 minutes on the trail with minimal knowledge.... biggest thing to have for it would be the big socket for the castle nut.

I haven't done it on the trail (I just drove it home after getting recovered off the trail as 2wd wouldn't cut it).... but I have done it at home in my garage..... on my FJ once and replaced both on an older tacoma I picked up.
 
#18 ·
@Virtual-Chris you ask great questions! I have personally experienced and/or witnessed trail failure of inner tie rods, cv axles, RLL, coilover lower shaft, rear shock upper breakage, steering rack, UCA bushings and balljoint, and probably others. I carry spares for the first three items (these are the most common) plus outer tie rod, spare rear shock, spare wheel bearing assembly, plus a 35mm socket for the cv axle and fully charged torque wrench, and PS fluid, engine oil and a variety of general tools + smaller parts (fuses, clamps, bolts etc). When loading up for a run I ask myself the question, “What failure/breakage would strand me that I can simply carry a part or tool for?“ and pack it. I probably overpack because I travel long distances to run hardcore trails 😁

As for the question of a front locker leading to cv axle failure, I disagree - I can say from personal experience that it does not, as long as you don’t do really stupid maneuvers like making sharp turns with heavy throttle while locked! Also I run an eLocker so don’t have the issue I’ve more often seen of air hose failure.
 
#19 ·
  • 2 inner and 2 outer tie rods (they often break in pairs)
  • spare serpentine belt
  • front cv shaft from too much unlocked wheelspin or binding while locked.
  • rear ring and pinion (no sense in carrying a spare. Just have a plan and wheel with friends or upgrade the rear end)
  • Seen a steering rack fall apart on a trail.
  • Stock rear lower links bend

These are spare parts I carry for rock crawling. 6+ rated trails
 
#23 ·
Best philosophy is to not off-road alone. Bonus points for riding with folks that have the same rig.

Use your head and keep reminding yourself that you have to drive home. It is not smart to follow a trailered rig and expect a positive outcome.

I’m getting old. The kids and I have more fun off-roading to a good vantage point and watch other crazies bust their rigs. We often chip in to help, watch wayward kids, dogs and help with logistics while the broken vehicle being worked on.

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#27 ·
Between @debFJVT and @Iconic_ seema like an FJ can be built on the side of the road if needed 😁

On my side:
Bent stock rear lower control arm
Bent panhard
Bent outer tie rod
Snapped rear sway bar link
Broke about 3 tire inflate pivots (thanks rocks)
Lost around 5 mirrors (thanks trees)
And for some reason I keep breaking my CV boots, I think 5 since I did the diff drop, so weird

Broke in 2 the OEM gas tank skid... But that's what it's for, didn't hit the tank

And once I went down from a hill so hard I literally folded my rear bumper to the rear door (had it reinforced after)

Good times 😎✌
 
#40 ·
Front swaybar links for sure. They either bend or break. If broken they will most definitely take out the outer CV boot, nuking everything in grease.
Easiest fix...., swap out the CV and replace the swaybar link. If you don't have a link, disconnect both and tie up or remove the swaybar.

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