Lessons Learned High Mileage Knowledge

[Random88]

We have two discos, the oldest 1994 300TDI with 365Ks, had it since new. Now with that experience it baffles me why there isn't information beyond the service manual. In going through this forum there are gems of knowledge sprinkled through it but I haven't found anything useful for high mileage owners e.g.
For 300TDIs (example mileages only)
250,000 replace waterpump, and connected rubbers hoses
XXX,XXX replace thin hose bottom of expansion tank
XXX,XXX replace rubber coupling in drivetrain
etc etc

Nearly everything that has gone wrong (not that many) with our Discos have been said the be known problems at about that age!
It appears that there are very well known failures at predictable times, why is are they not documented for owners and prospective buyers?

[steveG]

My view is that maintenance is such a variable and personal thing that its not possible to make such a list

IMO:
If you've got a lift or do heavy towing then you're likely to need to replace rotoflex couplings more often.
If you've got cooling system hoses over 10yrs old then you are gambling
If you do hard offroad work you need to replace suspension bushes more often.
Lots of corrugated roads will eat shocks.
I'd do a preventative head gasket change at around 220K, but others would beat me to death with a stick for such a stupid practice.

Some people prefer to invest in preventative maintenance, others prefer to replace based on condition. Either is a reasonable approach, but adopting an on-condition regime without regular inspection just results in failures.

You will NEVER get consensus on a preventative maintenance list.

Steve

[Hay Ewe]

My view is that maintenance is such a variable and personal thing that its not possible to make such a list

IMO:
If you've got a lift or do heavy towing then you're likely to need to replace rotoflex couplings more often.
If you've got cooling system hoses over 10yrs old then you are gambling
If you do hard offroad work you need to replace suspension bushes more often.
Lots of corrugated roads will eat shocks.
I'd do a preventative head gasket change at around 220K, but others would beat me to death with a stick for such a stupid practice.

Some people prefer to invest in preventative maintenance, others prefer to replace based on condition. Either is a reasonable approach, but adopting an on-condition regime without regular inspection just results in failures.

You will NEVER get consensus on a preventative maintenance list.

Steve

This is pretty much how the aviation industry works.
a check / inspection program combined with hard time, either hours / landings / cycles completed or calendar.

For example (trying to relate a D2a TD5 item to an aviation type check)
the rubber rotorflex on the rear drive shaft.
Insp every 10,000km for obvious visible damage
Insp Every 20,000km for delamination, elongation of holes and out of shape
Retire and replace every 100,000km

engine coolant hoses
Every 10,000km inspect for bulging, kinks, distortion and leaks.
replace every 100,000km or 10years which ever comes first.

Brake lines and fluid will be the next project that gets done on our D2a, based on calendar.

I have a Haynes manual, have had for every vehicle I have owned and I cant refere to it right now but like an aircraft manual, it will list all tasks that the manufacture deems to be checked at that interval. when your vehicle reaches the end of the that list, you start again.

I agree that they don't list every, like coolant hoses and that is where it becomes subjective to the environtment that you operate in. Also, the knowledge shared.

We have a fleet of helicopters that we have done modifications on that many other operators have also done. Bell have only recently started including those modifications in new build aircraft - Industry feed back.

(my aviation experience is 19 years on a range from Boeing narrow body to DHC6, Bell 212 / 412 and S76C)

Hay Ewe

[DiscoMick]

I have a Haynes manual and have downloaded the free RAVE manual, which are both helpful.
Our Disco 300Tdi is a similar age and distance to yours.
At this age, I just assume everything is on the way out so, apart from fixing things that break, I'm trying to do regular preventative maintenance. for example, next on the list are a timing belt and suspension/steering bushes.
The problem is, things I overlook bite me now and then.
All part of the fun I guess.

[Sitec]

I have a Haynes manual and have downloaded the free RAVE manual, which are both helpful.
Our Disco 300Tdi is a similar age and distance to yours.
At this age, I just assume everything is on the way out so, apart from fixing things that break, I'm trying to do regular preventative maintenance. for example, next on the list are a timing belt and suspension/steering bushes.
The problem is, things I overlook bite me now and then.
All part of the fun I guess.

Mick.. The explanations below are pretty well spot on! Yeah, it always seems like waisted money changing something that 'looks fine'... but its not. Another way of looking at things is, all oils, fluids etc should be changed often. That goes without saying. Things like belts, hoses, filters, uni joints, steering joints, brake pads etc should be changed when due or within a specific timeframe.. If they fail, they will cost you an engine, gearbox, vehicle etc... Other things like batteries, wheel bearings, exhaust, panel work, fixtures need to be monitored, but if they fail, yes they'll cause an inconvenience, but won't cost big bucks to fix. Your key things are cooling system and coolant, all oils and filters (don't forget to do the air filter!), timing belts and drive belts. Look after these and the car will serve you well.

[dadsDisco1]

[QUOTE=steveG;2077386]
I'd do a preventative head gasket change at around 220K, but others would beat me to death with a stick for such a stupid practice.

I'm coming up to 220k in my 97 v8i and sure enough I believe there's enough evidence to suggest an imminent head gasket failure. She runs like a dream now and most wouldn't know it's coming but I know from other forums ALL the warning signs and fear ignoring this problem will not make it go away, so now to find a reasonably priced place to get the heads machined!

[ramblingboy42]

[quote=dadsDisco1;2077554]

I'd do a preventative head gasket change at around 220K, but others would beat me to death with a stick for such a stupid practice.

I'm coming up to 220k in my 97 v8i and sure enough I believe there's enough evidence to suggest an imminent head gasket failure. She runs like a dream now and most wouldn't know it's coming but I know from other forums ALL the warning signs and fear ignoring this problem will not make it go away, so now to find a reasonably priced place to get the heads machined!

If it's done as preventative maintenance you won't need to machine your heads.