Below is a list of recommended spare parts that should be carried   and pre-expedition inspections that you should carry out.  Contributed by Brian Stephens & Rod Linnett.

Please note that the spares list is primarily aimed at travelling alone and/or   doing long distance touring and off-roading as well as being self suffiicient.   It is mainly aimed at this aspect, as well as the fact that getting parts for FSJ's here in Australia, although not entirely difficult, it's just that it will either cost you plenty, because you need it urgently, or because of where you are.  So the advice given here is to be able to cater for just about any breakdown situation alone, other than a major failure like a broken piston, dropped valve etc.  And besides there is no alternative to being prepared !

Spares

Cooling system

Thermostat, 1 complete & 1 with the centre cut out, gaskets & spare housing

3m of heater hose    Radiator hose - top & bottom     1 bypass hose        1 water pump

Coolant - enough to fill radiator, approx 12 to 13 litres, (or concentrate) depending on it's size.

1 bottle of 'Bars Leaks' or similar for radiator repair         Various array of hose clamps

Oils, Fluids & Grease

5 litres of Engine oil    10 litres auto transmission oil for auto and/or transfer case/power steer unit    QT oil (if QT equipped)

2 litres gear oil for diffs and/or 2 litre gear for manual gearbox     1 tube of wheel bearing grease

1 litre brake fluid    1 litre distilled water (for battery)

LPG upper cylinder lubricant as required (if LPG equipped)

Engine, Fuel System, Mechanical Spares

3m fuel hose (can be used to gravity feed fuel if necessary)

fuel filter     old mechanical fuel pump ( for those equipped with electric fuel pumps)

1 complete set of belts to suit vehicle         2 engine mounts         assorted vacuum hose

2 Universal joints        1 complete front wheel bearing assembly

1 complete rear wheel bearing assembly

Ignition

Spare LPG 3-way switch (if equipped)

1 set of spark plugs - not necessarily new ones, even the last set that was changed will do

4 Ignition leads (even old ones, as long as it works, make sure 2 are the longest length needed)

1 coil - distributor lead        Jumper leads         Torch or 12 volt lead light

1 distributor cap & rotor        1 ignition coil        1 ignition module (Expensive spare, but if it breaks, you stop)

Suspension

6 shock absorber bushes        2 rear U-bolts         2 spring centre bolts        

4 spring clamps  (good quality Jubilee clips will do)

Service Parts, Tools & Extras

1 Service kit for auto trans - Sump gasket & filter - can be very handy should you damage the sump on a rock or get water intothe transmission.  You can drop the sum, panel beat, repair the hole with your radiator/ fuel tank repair kit & refit & refill.

1 Air filter (paper type) 2 for dusty conditions      2   Oil Filters       

10 Outer foam bands for Oil soaked air filters.  * Oil soaked foam type air filter is far better for dusty conditions.  The outer band can be changed daily, washed and re-treated & re-used.  Also a bottle of oil for Air Filter treatment.

1 set of wiper blades        2 ligh tglobes for headlights & assorted fuses

6 tyre valves & dust caps & valve removing tool         jack         tyre levers and/or 'tyre-pliers'

2 inner tubes & comprehensive puncture repai kit & a pump or compressor etc

4 Exhaust clamps & material to make exhaust hanger  (piece of truck mudflap is perfect)

Exhaust manifold bandage & Exhaust cement         Fuel tank & radiator repair kit

Electrical tape, Heavy duty duct tape, Gasket cement, Silicone (RTV) or 'form-a-gasket'

Roll of gasket material, scissors        2m No.8 wire

Tin of nuts & bolts, split pins etc         6 spare wheel nuts

Plastic funnel (& filter) for pouring fuel, auto trans & engine oil

Pump for getting oil into diffs and transfer case

Necessary tools such as sockets, spanners, wheel bearing spanner/ socket, wheel brace, spark plug spanner, scredrivers etc

Water & Survival

This is treated separately as a section for human consumption, remeber the FSJ can have al lthe sapres, but if there is no-one to drive it, is it really broken down ?

20 litres (minimum) of water - for you, not the FSJ.....and carry a water bag on the front.  Obviously the amount of water you carry will depend on how many are in the vehicle.

UHF radio, satphone, HF Radio -whatever is most practical for the region or achievable - but minimum should be a UHF

10' x 10' tarp  - can be used as a ground sheet, shelter and collecting water

First-Aid Kit

Inspections

Suspension Inspection

Front  LH and RH U-bolts, springs, shocks & mounts

Front sway bar, mounts & bushes, steering damper & mounts

Rear  LH and RH U-bolts, springs, shocks & mounts

Front & rear spring clamps

Engine Compartment Inspection

Engine oil level        Auto transmission fluid level        Brake fluid level

Radiator water level & condition & over flow bottle

Air filter        Engine mounts

All visible LPG components (use soapy water to detect leaks on shut of valves etc)

All belts, hoses and clamps        Battery water level, terminals & battery cradle

Wires to starter motor & solenoid         Auto transmission fluid cooler lines & oil cooler

Windscreen washer water level        Upper cylinder lubricant level (for LPG vehicles)

General Body & Exterior

Fit & condition of mud-flaps        Fit & condition of roof rack & any items fixed to it

Condition of wheels & tyres (including spare tyres and/or tubes)         Poly-Air springs (if equipped)

Clean all glass, wipers, mirrors, headlights, indicators, spot-lights

Check oil level of front & rear diffs         Check transfer case oil level

Check all fuel lines, filters & fittings         Check all brake lines, handbrake cables

Check all driveshafts for missing weights, lubrication and overall condition

Miscellaneous Items

Check exhaust manifolds & mufflers, hangers, tailpipe