So, I have had a few days to reacclimate to civilization...and I'm ready to go back to the desert...
Anyway, here is the close-out report for this trip:
Damage/Parts/Repairs
1. rear "glass" sensor went bad the last day in the field. I just unplugged it for now.
2. Forward propeller rear CV boot failed somewhere and disappeared. MacGuyvered in the field, replacement arrives tomorrow along with the special tool so I can put those stupid clamps on properly this time.
3. Intermediate steering shaft boot missing (?) Not certain of this one yet, it appears some had one and some didn't however might relate to next item.
4. Power steering gets tight and stiff and "creaky" after about 200 miles at freeway speeds. Odd in that cannot find anything wrong with the pump or any of the linkages, yet a shot of Endura on each of the U-joints corrects the issue instantly gotta look into this one more...
5. Gotta get that lift in. Bert was a straight up TANK the whole trip crawling up and through stuff that had lots of people scratching their heads. Also front tires rub on the pinch weld on sharp turns....a symptom of being loaded heavy on stock style mushy suspension with knobby Toyo ATIII tires, but not on street tires. (225/75/R16)
6. Still getting a random, self clearing MIL code for random misfires on #6. Highly intermittent. Suspect its time for new fuel injectors as compression is within standards and everything else related is new.
7. Need to repair gas tank skid plate and look into replacement gas tanks even though my field repair to the puncture is performing.
8. the sensor in the exhaust system next to the rear CV prop shaft is working but the cable is hanging and the jacket is a bit shredded likely from the boot failure.
9. Time to seriously investigate the transmission. Had some serious over-rev issues on the freeway intermittently. Sure, they are notorious for not shifting when they are supposed to, but there were far too many hard shifts...a few times I thought the thing was going to jump out from under the Jeep in pieces. This is only an issue at highway speeds and much worse when using cruise control. Suspect the transmission speed sensor is on its last legs or out of adjustment (if any)
10. Fog light switch has failed. If the headlights are on, the fog lights are on. the pull out is not functioning at all.
11. Key fob lock/unlock function failed again. Tried all four brand new fobs.
12. Still cannot get the white reverse lights to work. Going to have to spend a day troubleshooting that circuit as the bulbs are new and the harness rings out. probably the sensor/microswitch.
13. While I didn't need the other ones, the gas tank incident has me convinced it is time to fab skid plates. I'm not paying the prices for 3rd party plates OR the OE plates if they can be found.
14. The serpentine belt failed. this happens, and there is now a 3 year warranty one under the hood and a spare under the seat.
15. Hood vents. I now understand the need. While I didn't have any overheating issues (other than the climb up to Sinbad Overlook where the transmission temp light came on 3/4 of the way up)
Starting Mileage was 170500. Final mileage was 173793. Avg Highway mpg was 13.9. Avg off highway mpg was 16.6.
In addition to the long planned and thrice attempted lift, I need to finish my custom bumpers. I also have to find, restore, and install the OE rally lights to make the wife happy. I also need to finish my pull out countertop and my slide out food/equipment storage system. I skipped those two for this trip as load weight became a pretty serious issue.
Finally I either need to install a snorkel or a K&N cold air system. That stock air box and filter collected just as much dirt and bugs as I did. (Went through 3 air filters on this trip!)
Finally, cosmetics. The bed liner coat on the lower half still looks silly to me, but it functioned EXACTLY as planned. Need to do that to the front grill as it looks like the milky way from all the gravel hits from the trip with the white showing through. Need to install a rear rally light/back up light and a rear yellow flasher in the spare tire mount.