The Essential Off-Road Garage

10 Tools You’ll Need To Modify and Maintain a 4X4 Vehicle

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Words and Photos by Peter Boyer

This article isn’t about creating a dream garage. Who doesn’t already think about a large clean space with a two-post hoist, cabinets of tools and having a designated space for mods and tune-ups to their vehicle?

Even though my garage is the best that I’ve ever aspired to, I have paid my dues tooling vehicles in cold machine sheds with dirt floors, in the Northern Ontario bush and even under a tarp in -30 C (-22 F) temps. Can work be done in these conditions? Yes. But I tip my hat to those who do their DIY mods (or mechanical miracles) in adverse conditions.

Tool preferences and work environments are often dictated by the mod or tasks, skill level, and budget. Although some tools and equipment are necessary for a professional shop such as an engine hoist and a hydraulic press, tools for weekend wrenchers in their garage may be limited and choices of the mod should be determined carefully. This begs the question of what tools are needed for the ideal workshop/garage space to do basic maintenance, repairs and modifications (e.g. suspension, bumpers and winch upgrades).

The go-to tool I reach for may not be your first choice, and anyone who wants to swap their engine will immediately realize that an engine hoist (or a hydraulic press for that matter) is not on the list below. While tools and systems for such advanced tasks are essential, some can always be borrowed from a friend or rented (in most instances) when needed.

For the DIY projects that I complete, like modifying a suspension, replacing rear axle seals or just changing fluids, swapping tires, and rigging aftermarket accessories, my garage setup is ideal. Below is a list of my tools and equipment that have proved their value time and time again.

1. A Solid Fixed Workbench with a Steel Top and a 6” Vise

I consider my workbench with its solid surface and 15 cm (6 in) vise one large tool. A number of parts can be secured for repair with the vise while the top has the ideal space, durability and function. It’s generally easy to maintain and I am thinking it will last forever. My steel top is also fire-resistant, making it handy when mechanical parts need to be heated.

I made the frame of the bench from scrap wood, screwed it together and lagged the base to the garage wall using studs. It’s immovable and has withstood some pretty heavy abuse. I ordered the top to size from a local fabrication shop for less than $200 and the vise was purchased from Princess Auto for $160.

Approximate Cost: $360

2. Socket Set and Box-End Ratchet Wrenches.

It’s common to have a collection of screwdrivers, pliers/vise grips and other general-purpose small tools. However, you’ll need a set of quality sockets, drivers and adapters with ¼” to ½” drives in both metric and imperial measurements.

If you use an impact wrench, impact sockets that are strong enough are required to withstand the high torque. I recently purchased a set of extra-long, boxed-end ratchet wrenches for when I work on my project Jeep. It can be difficult at times to get to a socket on a suspension and or have that extra leverage needed of a long wrench. While useful, these tools are expensive so look for sales whenever possible.

Approximate Cost: $400

3. Floor Jack/Jack Stands/Ramp

For a number of modifications on a Jeep or 4X4, you’ll need to raise the vehicle securely for efficiency and personal safety. While ramps, jack stands or floor jacks range in price, they are not something to scrimp on and should be doubled up. If you opt for jack stands, be sure they include some kind of locking mechanism for security and rated for the weight they need to support.

Approximate Cost: $500

4. Impact Wrenches – Ratchet and Gun 

Several brands of battery-powered impact guns are great to have including those from Milwaukee, DeWalt and Ryobi. I have also used air impact guns but prefer the simplicity and portability of the battery-charged models. Having two guns may be overkill, but one is  ½” drive and the other 3/8” drive.

They are both M12 Milwaukee and conveniently use the same charging system, battery and can fit a variety of adapters and extensions. While they are powerful, the gun-style model is the most universal and I use it the most. Impact wrenches are not always my go-to tool, especially on older vehicles where fasteners are rusty and need some strong torque to remove but they make light work for removing/installing easy-to-access parts (including wheel nuts).

The ratchet-style model is more useful for accessing tight spaces like when I installed a pair of Victory 4X4 bumpers on my 4Runner. They eliminated the need to twist those almost-inaccessible bolts by hand.

Approximate Cost: $400

5. Tool Storage

My rolling toolbox was purchased at a yard sale for almost nothing and it serves me well. I also installed commercial steel cupboards above and below my workbench. If you’re on a budget, you can easily make your own open shelves from wood.

From portable tool boxes and rolling tool chests to 22-gauge commercial steel cabinet sets, you can spend as much or as little on tool storage solutions as you need and space dictates. Regardless of your choice, organized tools make projects a lot more convenient and easier.

Cost: Prices vary based on space and tools

6. Torque Wrenches

The tightening of most components on vehicles in the 1950s and 1960s was usually obtained by feel. Today, with the advancements of technology, critical torque settings are now established by manufacturers.  A torque wrench is necessary to prevent over-torquing and damaging sensitive parts. I use two types, a ⅜” drive version (that is surprisingly accurate) and a modern 1/2” drive click wrench that I purchased on sale.

Total Cost:  $50

7. Oxy-Acetylene/Propane Torch

I keep a portable MC cylinder of oxy-acetylene under my workbench as well as a light propane torch. While propane and oxy-acetylene work well to loosen rusty bolts and weld parts together, there are a few reasons to have both.

Some of the advantages of oxy-acetylene are it burns hotter than propane, can be adjusted to a fine flame (making it easier to control), and is great for simple welds. Oxy-acetylene tanks are available in many sizes to take on larger projects, but I opted for the smallest MC tank size for easier transport.

Similarly, propane can be used for welding in some instances with a high output torch. It’s also much cheaper than oxy-acetylene and is available in most hardware stores.

Approximate Cost:  Propane: $50

Oxy-acetylene: $400

8. Multimeter

For years, I trouble-shooted old-school point-to-point wiring with a 12V light bulb and alligator clips soldered to automotive wire. Now, I’m happy using a multimeter, which is a lot more versatile.

With the number of point-to-point wiring on most 4x4’s like power blocks, auxiliary lights, winches, fridges, solar systems, and trailers, you’ll inevitably need a dependable and accurate method of diagnosing electrical problems. Designed to measure voltage, resistance and continuity and current, a multimeter is small and light enough to bring along on any wheeling trip in the event of electrical issues.

Approximate Cost: $20

9. Oil Catch Pan    

While not an absolute necessity, since an old 5 L (1.3 gal) oil jug or even a large foil braising pan is an alternative, it’s nice to avoid making a mess when changing and recycling fluids.

Approximate Cost: $40

10. Power Washer

I live in Central Ontario in a snow belt near Lake Huron. For at least four months of the year, my vehicle is exposed to highway sand and salt. It’s tough working under a dirty vehicle so a pressure washer is a must-have tool to clean your vehicle. You’ll want to opt for the underbody nozzle adapter. Trails, too, are the culprit of mud and various debris and it’s good practice to give your rig a blast after a day (or days) off the grid.

Approximate Cost: $250-plus

There’s a lot of pride in owning a 4x4, especially if you perform various DIY projects. Having the ideal space and necessary tools to do each job makes it all that more enjoyable and satisfying.