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Jims 03 Safari AWD

14099 Views 153 Replies 21 Participants Last post by  NoQuarter
Took a 6 hour road trip to pick up this 2003 AWD Safari with 123k miles.
This trip I got 16.8MPG and afterwards I checked the tire pressures, and they were about 20PSI!

I filled the tires properly and took another 6 hour trip today and netted 17.6 MPG! Pretty happy with that.

After the drive home without incident, we started the cleaning process and general maintenance.

Passenger side headlight was dim and both corner lights were out. Drained the water out of the light housing, dried out the bulb socket, replaced both corner bulbs now all the lights work and the headlight works properly. The water was causing a current draw (I think) thus dimming the headlight bulb.

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The lower body is all rusted out and the plan is to cut them out and weld in replacement panels
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The engine bay was nice and clean with no evidence of oil stains anywhere
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Had a pleasant surprise when I checked the coolant. The cap is pretty skanky, but the coolant looks fresh
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Same with the brake fluid. The reservoir looks like it has some left over smudge, but the fluid looks fresh.
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I had some drips from the rear diff and finally got a good look under there. The pinion seal is leaking, and the oil is slinging all over. Took it on another road trip today despite the leak and it got.... interesting. I now have oil mist all over the rear doors it got so bad. Didn't smell too good with the oil on the exhaust pipe.
Turns out... someone left a hose attached to the fill hole so they could keep the oil topped off :eek:
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I'm going to get it all cleaned up and replace 7, 18, and 19. Clean out the inside of the diff, inspect it and take it from there.
I will also order new drain and fill plugs once I figure out where to find those.

edit: it seems there are no drain plugs on these, but the fill plug I found at AutoZone thanks to @AstroWill Linky!!

Any tips/advice for this project is appreciated :cool:

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Electric is all that is left. Not going to stow the winch cable like this. I will remove the hook and store inside.
The welding really tightend up the fit so I just went with it and forced it on scraping the pain off of the shackle mounts. Then used the frame/leverage to pry out the sides a bit and got a better fit.
Re-paint another day.

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Hey I saw this on Matt's Offroad Recovery Youtube channel Yankum rope

The grooves allow you to store the loop and it won't get damaged while drive since it is recessed.
I love the bumper! I wish I had the space, time, skill to do that.
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More info on your Radio please. Do you have a link? I have a good bluetooth, XM radio but I want a touchscreen and better screen for my rear camera
1 - 3 of 154 Posts