Hello,
Have decided to use downtime to give of my 2004 (2002 built) 4 life a little care and attention. The front end is looking a bot tatty so have removed the front bumper ready to repaint the front panel and refirb the bumper. No surprises several bolts sheared in the process despite lots of penetrating oil sprayed on in the previous few days.

Fortunatley I think i have got to the rusty bits behind the bumper just in time so wire brushing and paint in due course.

In the meantime I wonder if the forum could help with bolt sizes please as I am about to order some stainless replacements online. The supplier is just across town but probably like many of you I am shut up so can't take the existing bolts to get them matched.

Measurents I have made of the diameter of the threads are:

Sump Guard and Bumper Supports 10mm (14mm socket)
Further sump bolts and general fixing bolts 8mm diameter (12mm Socket)
Now for the odd one fixing bolts for the tray supporting the bottom of the bumper appear to be 6mm (10mm Socket)

Does this sound about right to you or is there a more figures/ specs I should be using.

It's a while since I have had the spanners out as normally using the truck every day I have been reluctant to take it apart knowing it probably would not go back together very quckly! Many thanks for your help.

BW Turtoise

Quote: Turtoise wrote in post #1

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Further sump bolts and general fixing bolts 8mm diameter (12mm Socket)

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Be fair Kurt, you're dealing with metal dinosaurs with pointed badges on them...at least he's not faced with the fuel tank refurb and all those quirks.

Many thanks Krutley. That helps alot. Did my bolt diamaters sound about right? Some of them were a bit softer than cheese.
any idea where I can get the white plastic 'half moon' clips that the top edge of the bumper slots back into. It was the last one to come out and I had a fight with it. I won! (but need a replacement now ......)

The kids see the truck as an hierloom so they'll be upset if I don't look after it. Even if they can@t drive it anywhere due to deisel bans .... Nice to have something to pay with over the coming weeks. Thanks for your help.

P.s since we last spoke many moons ago about turbos, had the truck chipped. Doesn't go faster but a bit more grunt towing up hills. They also tamed my troublesome turbo before dong the work too.

Not done the tank yet, touch wood. Mind you it has been liberally sprayed coated with wax every couple of years as has the underside of the bed. Anyway quite fond of the beastie so time to look after it.

diameters sound about right to me bud
not sure what you mean by the half moon clips, dont remember seeing them last time I put a bumper back on


a classic wouldn't be a classic without
a rusty front cross member
a flashing green 4x4 light
overboost EML light issues
seized front caliper sliders
an overheating problem
sticking electric windows
a strange clunk from underneath
a spare wheel mech rusted up
a dented tailgate
a de-laminating front pulley
rusty stack pipes
H4 headlight bulbs stuck
sticking load sensor
rotten rear arch flaps
and excess wear on front nearside tyre

@krutly forgot one thing, a part from mikeinatruck!

Thats a pretty accurate list Mr K ... you forgot a revved EGR cooler and valve though lol...

Thant is indeed a long list. Quite pleased that I have managed to deal with or keep most at bay.
Egr Valvel - that was deleted with the remap although all the hardware is still in place so it looks standard.
Waxing has kept the spare in good nick but agree with all these, Replacement rear aluminium flaps hens teeth. One in europe at last enquiry, but not a pair. Thinking of losing these and fabricating some new ones out of heavy conveyer belt rubber and riveting/ bolting them in place.
Tailgate done- took me back years with all the prep and 'plastic padding'. Got spray cans made up locally.
Half mooon clips aren't half moon. had a look again they are like an old book of matches folded over central under the headlamps.
Oh and the 4X4 solenoid id beinf stroppy to an the moment so agree with the clonk from underneath. And the moss growing out of my leaking canopy! But thanks very much for you comments on the bolts and the work checklist. BW

Thant is indeed a long list. Quite pleased that I have managed to deal with or keep most at bay.
Egr Valvel - that was deleted with the remap although all the hardware is still in place so it looks standard.
Waxing has kept the spare in good nick but agree with all these, Replacement rear aluminium flaps hens teeth. One in europe at last enquiry, but not a pair. Thinking of losing these and fabricating some new ones out of heavy conveyer belt rubber and riveting/ bolting them in place.
Tailgate done- took me back years with all the prep and 'plastic padding'. Got spray cans made up locally.
Half mooon clips aren't half moon. had a look again they are like an old book of matches folded over central under the headlamps.
Oh and the 4X4 solenoid id beinf stroppy to an the moment so agree with the clonk from underneath. And the moss growing out of my leaking canopy! But thanks very much for you comments on the bolts and the work checklist. BW