Snags and spares to carry in an overland truck
Lists of parts are always a good way to start a heated debate on spares to carry in an overland truck. I am not trying to do that here; I am just listing the items that we have decided to carry and which may be useful for others to start their own research! We have been researching what to take with me on a long journey (several years) in sometimes remote areas with no Iveco dealers nearby, where I will need to be as self-sufficient as possible.
For the reasons set out under the tab “Choosing the Truck”, we chose a new vehicle rather than over-hauling and updating someone else’s ‘old favourite’. On balance, the persuasive arguments for us were: (i) the increased reliability; (ii) the far more economical fuel consumption; and (iii) the modern features and comfort for life on the road. I have a background in electronics and avionics, so am not put off by the prospect of using my diagnostic equipment to trace faults; in fact sadly I must say that I quite enjoy it!!
Over the last few years I have monitored the Iveco chat-room/forums and it seems that very few major mechanical issues arise with Iveco Dailys. Most problems that arise seem to relate to electrical wires/connector issues and the vacuum system. The feedback on these chat-rooms, my other research and my previous experience have driven me to reach the following conclusions:
Major mechanical failure. This is a low probability, so these will have to be dealt with when (or, more optimistically, if ) they happen. You simply cannot carry spares for everything that could possibly go wrong with any vehicle.
Minor mechanical issues. These are a higher probability, but the most likely are:
- oil leaks (which can be either patched up, or more oil poured in, until the spares are shipped to us); and
- temporary mechanical fixes (which can be improvised ‘in the field’ to get us moving until it can be fixed properly).
Electrical issues. We are very unlikely to find trained technicians in the countries we will be visiting, so I need to be self-sufficient. The various spare sensors are small and easy to carry, but test equipment is required.
Fuel quality. This is likely to be an issue (see tab “Fuel Issues”), but I have an extra pre-pre-fuel filter and am taking one spare injector to help with fault diagnosis if required (although these are not cheap!!). I also have an option if the DPF cannot be regenerated.
Tyre snags. I have chosen the standard split rims with tubeless XZL tyres fitted. We have one complete spare wheel plus an additional spare tyre. The wheels and tyres can be used with or without inner tubes, but we will also be carrying two spare inner tubes. I have a set of Tyrepliers (a great tool from Australia for breaking the bead) plus lots of patches, plugs and glues to carry out full tyre repairs.
Spares List
Given all of the above, here is the list of main spares we will be taking for my 55S17W (I have not included all the usual sticky tape, hose repair kit, pipe clips, string, threaded rods, nuts and washers etc.):
| Part Number | Description | Detail | Quantity |
| 5801259656 | ELECTROVALVE | Turbo waste gate vacuum valve | 1 |
| 504385557 | ELECTRICAL INJECTION | Fuel injector | 1 |
| 504382373 | SENSOR | Fuel rail pressure sensor | 1 |
| 504346675 | TYRE INFLATING VALVE | Tyre valve | 1 |
| 504341691 | SEAL GASKET | Fuel injector seal | 4 |
| 500054702 | FUEL FILTER | Pre-filter | 4 |
| 2992662 | FUEL FILTER | Pre-Pre-filter! | 4 |
| 504307953 | SENSOR | Intake manifold | 1 |
| 504135503 | SENSOR | Lambda | 1 |
| 504131270 | GASKET | Cat rear and silencer front | 2 |
| 504131269 | GASKET | Cat front | 1 |
| 504129943 | ELECTRON.TRANSMITT | Crankshaft | 1 |
| 504092335 | V-BELT | Alternator | 2 |
| 504087247 | V-BELT | AC Compressor | 2 |
| 504061450 | RELAY | 20A | 1 |
| 504057813 | ALTERNATOR | 140 Amp | 1 |
| 504049024 | RELAY | 10/20A | 1 |
| 504048261 | SENSOR | Camshaft position | 1 |
| 500382599 | TEMPERATURE TRANSMITTER | In Thermostat housing | 1 |
| 500351992 | HEATER PLUG | Glow Plug | 1 |
| 500341925 | RELAY | 50A for EDC | 1 |
| 5801287850 | STARTER MOTOR | Starter motor | 1 |
| 69503673 | PUMP | Fuel pump – electric | 1 |
| 69502946 | SENSOR | EGT Mid CAT | 1 |
| 69502363 | SENSOR | EGT Front CAT | 1 |
| 69501120 | RELAY | In engine fuse box | 1 |
| 42559960 | GASKET | Transfer sump plug | 1 |
| 42560737 | FUSE | 500A brown | 2 |
| 18192490 | FUSE | 150A orange | 2 |
| 42556403 | FUSE | 70A brown | 2 |
| 42556402 | FUSE | 50A red | 2 |
| 18096190 | FUSE | 60A-BLU | 2 |
| 18095990 | FUSE | 40A | 2 |
| 16715990 | FUSE | 25A | 2 |
| 16715890 | FUSE | 20A | 2 |
| 16713890 | FUSE | 15A | 2 |
| 16713790 | FUSE | 10A | 2 |
| 16711990 | FUSE | 7.5A | 2 |
| 16711890 | FUSE | 5A | 2 |
| 16710090 | FUSE | 3A | 2 |
| 16627190 | FUSE | 30A | 2 |
| 11055990 | FUSE | 20A | 2 |
| 16508460 | WASHER | Sump plug | 2 |
| 2996465 | BRAKE PAD SET | Front pads | 1 |
| 2995655 | OIL FILTER CARTRIDGE | Oil | 4 |
| 1903669 | AIR FILTER CARTRIDGE | Air filter | 4 |
| 504008619 | SENSOR | Water pressure | 1 |
| 3802821 | Pollen filter | 1 | |
| 42567335 | Spring lock washer | For the transfer gearbox Hi/Lo gears | 1 |
Here are the Iveco specialist tools I carry:-
Part Number Description
99360186 Auxiliary belt fitting tool (for stretchy fan belts)
99342156 Fuel injector puller
99358026 Alternator free wheel spanner (needed to remove the pulley on the alternator)
99352115 Wrench for injector pipes
99360076 Filter spanner (fits oil and fuel water/sediment pre-filter)
99370205 Clutch centring pin
99355172 Wrench for wheel hub bearing adjustment ring nut
99341013 Reaction block (used for various jobs involving pullers)
99355047 Wrench for drive input and output flange fixing ring nuts (transfer gearbox)
99374459 Tool to correctly set the pinion seals
99347074 Puller for steering ball joints so tracking can be adjusted
Update 3 August 2017
So, after three and a half years on the road in Africa and South America, was the above list good?
Basically, yes. I’m happy with the spares and happily I haven’t needed many of them. Here’s a few notes on some of the spare parts:
Lambda Sensor
I’ve found that I need to replace the Lambda sensor every 50,000 km or so, which I think is probably due to bad quality fuel. It may be possible to clean-up the sensor and re-use, but for maximum reliability I decided to replace it with a new one (I have kept the old ones as emergency spares). Replacing it is quite a simple task taking only about 15 minutes, but the engine ECU needs to be reset so it knows that it has a new sensor.
Leaf-spring bushes
As we operate Cuthbert almost continuously at the maximum rear axle weight, the rear leaf-spring bushes have needed replacing. These weren’t on my original spares list, but I now carry these as spares. The good news is that same part is used for all locations on the front and rear springs, so one spare bush can be fitted in any location. The Iveco “SPRING SLEEVE” part number is 504011462 and they are quite cheap. I also bought the specialist tool to fit them (Iveco part number 99346052) but found I didn’t need it – they are quite easy to install. Follow this link to the Leaf Spring Bush Replacement page.
Silicone Pipe for Turbo Actuator
Cuthbert had a seized turbo actuator. I managed to free it and make the vehicle serviceable without using any parts. However, there is a small silicone pipe that connects to the turbo actuator. Over time, this small pipe becomes quite brittle – not really surprising as it spends its life at some crazy temperature right next to the turbo! To repair the seized actuator, I had to remove this pipe and damaged it in the process. As a temporary fix, I cut the damaged section off the end of the pipe and reused the remaining part, but I wanted to fit a new pipe for maximum reliability. I hunted high and low but couldn’t find replacement silicone pipe in Ecuador (well, I found a factory that could make it for me but the minimum order was 1 km of pipe when I only needed 50 mm!!!!) For the Daily 4×4, the silicone pipe can only be bought from Iveco as part of the vacuum pipe assembly at a bargain price of over £450. However, for the Daily 4×2, Iveco sell a much smaller pipe assembly; the silicon pipe can be removed from this and used on the 4×4, which is what I did. The Iveco part number is 5801284389 and costs around £7. Follow this link to the Seized Turbo Actuator Link page.
Intercooler TVA Hose
Cuthbert’s intercooler TVA hose developed a split. I have also seen on Facebook forums that other Daily 4x4s have had the same problem. The pipe is an awkward, non-standard, shape and size; difficult to repair or replace. I managed a quick-fix at the roadside in Brazil using a Campbells’ soup tin! Eventually in the next town I found some tractor hoses that I could modify to fit. I have now ordered a spare pipe to carry (Iveco part number 504338273). Note that the Iveco parts catalogue shows it in the wrong place on the engine and calls it a ‘water pipe’ (yet another example of the poor-quality Iveco documentation!).
APU Pressure Switch
I have seen on the Daily 4×4 Users’ Facebook forum pages that the APU pressure switch is prone to failure. Although I’ve not had an issue with this part, I thought it prudent to add it to my spares list. Iveco part number 504256748 “PRESSURE PICK-UP”.
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