Vehicle Preparation tasks

Vehicle Preps Checklist (detailed)

TL;DR: A step-by-step pre-departure process to prepare any 4x4, van or expedition vehicle for safe, reliable overland travel. Work through this list at least a week before departure and again on the morning you leave.

1. Mechanical inspection

Engine & drivetrain

• Check engine oil level and condition (top up or replace if near service interval).
• Inspect coolant level and colour — milky or rusty coolant = flush/replace.
• Check brake fluid, clutch fluid and power-steering levels.
• Inspect belts (alternator, A/C) for cracks or fraying; replace if worn.
• Inspect hoses for soft spots or leaks.
• Confirm no oil, coolant or fuel leaks under the vehicle after parking overnight.

Transmission & differentials

• Check gearbox and differential oils if due.
• Ensure 4WD system engages/disengages smoothly (test high/low range, hubs).
• Grease universal joints and drive-shafts if grease-nipples are fitted.

2. Tyres & wheels

• Inspect tread depth (minimum 3–4 mm for mixed terrain).
• Check for cuts, sidewall bulges or embedded stones.
• Confirm all wheel nuts torqued to spec.
• Verify tyre pressures: road, off-road (reduced), and spare all correct.
• Carry a tyre repair kit, plugs, valve cores, and spare valve caps.

3. Suspension & steering

• Look for leaks around shocks.
• Check bushings for cracks or play.
• Confirm steering free play minimal and no knocking noises.
• Grease suspension pivots and ball joints if serviceable.

4. Electrical system

• Check battery voltage (12.6 V+ rested) and terminal tightness.
• Inspect for corrosion — clean and coat with dielectric grease.
• Test all lights: headlamps, indicators, brake, reverse, hazards.
• Confirm auxiliary power system (dual battery / DC-DC / solar) charges correctly.
• Pack spare fuses and bulbs.

5. Recovery & safety gear

• Rated front & rear recovery points securely mounted.
• Rated snatch strap (clearly labelled), shackles/soft shackles, gloves.
• Shovel, traction boards if available.
• Fire extinguisher (serviced, accessible).
• First aid kit checked and restocked.
• Hi-vis vest, reflective triangle.

6. Fluids & consumables

• Engine oil, coolant, brake fluid, ATF, gear oil (as applicable) — carry small top-up quantities in labelled bottles.
• Water (drinking + radiator top-up) in separate containers.
• Screen-wash and spare wiper blades.
• Fuel filters and air filter spare.

7. Tools & spares

• Toolkit covering all fastener sizes on the vehicle (metric/imperial as needed).
• Socket set, adjustable spanner, screwdrivers, pliers, tyre-iron.
• Spare belts, fuses, bulbs, hose clamps, electrical tape, wire, nuts/bolts.
• Jack, base plate, wheel brace, breaker bar.

8. Load security

• Secure all heavy items low and forward in the vehicle.
• Use tie-down straps or cargo nets.
• Check drawers and cupboards latch properly.
• Never overload roof racks — keep weight < 30 kg up high.

9. Paperwork & legal

• Valid insurance and registration documents.
• Breakdown cover details.
• Vehicle manual, recovery and service information.
• International travel: green card, border paperwork, warning triangles, hi-viz vests, beam deflectors, etc.

10. Pre-departure morning check

Task	Confirm
Fluids levels re-checked	☐
Tyre pressures adjusted for load	☐
All gear stowed securely	☐
Lights and indicators working	☐
First aid / fire extinguisher accessible	☐
Maps, comms & emergency plan ready	☐

Linked topics

• Beginners_guide_to_Overlanding
• Basic_Recovery_Techniques
• Technologies (for electrical and off-grid systems)

Editor notes

This page should remain practical and printable. Add new region-specific legal requirements or maintenance tips as appropriate.