Commissioning, Shakedown, and Long-Term Inspection

Pre-start inspection

• Torque marks (paint stripe across nut & bolt) on all major fasteners.
• Fluid levels — front differential, transfer case, transmission, engine, power steering, brakes.
• Brake system bleed complete; pedal firm; no leaks.
• Steering: no bind through full lock, both directions, engine off then engine on.

Static & low-speed

• Static steering test at idle — feel for hydraulic groan, listen for pump distress.
• Slow forward/reverse on a smooth private surface. Listen for clunks; watch mirrors for driveline shudder.
• Controlled brake application — even, straight, no pull.

Alignment

• Caster to target, camber near zero, toe set to spec.
• Alignment on a rack designed to work with solid axles when possible.

Re-torque schedule

These are conservative starting intervals — always follow component-manufacturer specs where they exist.

• U-bolts: re-torque after the first drive, then at 50 km, 500 km, and every 5,000 km.
• Track bar and steering fasteners: re-torque at 50 km, 500 km, then at each service.
• Wheel lugs: re-torque at 100 km and after any wheel removal.

Progressive validation

1. Parking-lot laps → residential streets → arterial → highway.
2. After each phase: inspect welds, fasteners, brake hoses, driveshaft joints, and fluid levels.
3. 500 km and 1,000 km inspections logged in the Reference Build journal.
4. Only after a clean 500+ km road period: easy-trail testing, with inspection after.

Long-term inspection

• Weld inspection: visual after every trail trip; NDT at intervals recommended by your inspector.
• Steering joints (drag link, tie rod, box, pitman arm) checked at every oil change.
• Wheel bearings — service interval affected by tire mass, use, and water intrusion.