Assessment and Inspection

Chapter 2 – Initial Assessment

First impressions

With the Unimog safely home in Narrabri, the real work could begin.

Although the vehicle was complete, running and capable of being driven, it was immediately apparent that a thorough inspection would be required before any decisions could be made regarding its future.

It actually started first turn and ran sweet as. 2 x noises coming from around the air cleaner area, ,my assumption is leaking air compressor head cylinder gasket and generator bearing...

Like many military vehicles of its age, the truck presented well at first glance but concealed decades of modifications, repairs and general wear.

The initial objective was simple: Determine exactly what had been purchased and establish whether the vehicle was suitable for restoration and future expedition use.

Walk around

First Test Drive and Cooling Concerns

One of the first tasks undertaken was a test drive to assess the vehicle's basic operation.

During testing, a coolant warning light illuminated on the dashboard, immediately raising concerns regarding engine condition. There was also a knocking noise coming from the front RH region of the axle.

Further investigation was carried out using a heat gun to verify actual operating temperatures. Fortunately, results indicated the engine was operating within normal temperature ranges, suggesting the issue was related to instrumentation or wiring rather than an overheating engine.

This early diagnosis highlighted the importance of verifying faults rather than assuming the worst.

Haven't located the knocking noise yet though !

Beginning the Investigation

As confidence in the engine increased, attention shifted toward a systematic inspection of the vehicle.

The bonnet, grille and front panels were removed to improve access and allow a more detailed examination of the engine bay, cooling system and front chassis. A defect register was started, and observations were documented as issues were discovered.

What initially appeared to be a simple recommissioning project was already beginning to reveal itself as a much more interesting undertaking.

Tarp and bows removed so i could get the tires, torque tube and rims off the back and to expose the tray for an inspection. Love the turret. bit of rust to fix up there, not too crazy though.

Early Repairs and Recommissioning

While inspections continued, a number of smaller defects were addressed to improve functionality.

Replacement seats and seat belts were installed, improving both comfort and occupant safety. A replacement rear chassis plate was fitted, and various lighting issues were investigated and repaired. Bushes were also replaced. All bolts were replaced with new 10.9 grade metric fasteners and all threads were cleaned and retapped upon reinstallation.

Electrical faults proved to be a recurring theme throughout the vehicle. Tail lights, indicators and associated wiring required attention, with several issues traced back to faulty components and previous repairs.

Although relatively minor in isolation, these jobs provided valuable insight into the overall condition of the truck and reinforced the need for a comprehensive approach to the restoration.

Establishing a Baseline

To better understand the condition of major mechanical components, servicing and inspection activities continued across multiple systems.

Oil Sampling

Before committing significant time and money to the restoration, oil samples were taken from major driveline components to gain a better understanding of their internal condition.

Oil analysis provides a snapshot of what is happening inside a component without the need for disassembly. Wear metals suspended in the oil can indicate the condition of bearings, gears and other internal parts, while contamination from dirt, coolant or fuel can highlight developing problems.

The results formed part of the overall assessment process and helped build confidence in the condition of the vehicle before major restoration work commenced.

Actual PTO sample from my Unimog below

At the same time, significant effort was invested into researching the truck's history, reviewing previous rebuild documentation and assessing earlier repair work.

The overall picture that emerged was encouraging. While the truck clearly required substantial work, it also appeared to possess a solid foundation worth investing in.

Defining the Restoration

By the end of the assessment phase, it had become clear that the project would involve considerably more work than originally anticipated.

Issues had been identified across the cab, electrical system, cooling system, driveline, braking system and various ancillary components.

Rather than undertaking isolated repairs, the decision was made to adopt a system-by-system restoration approach.

This decision would ultimately shape the remainder of the project and form the basis of the chapters that follow.

The objective was no longer simply to get the truck running and registered. The objective had become creating a reliable, mechanically sound Unimog capable of supporting future expedition travel.