Make use of the wagon's "secret compartments" to maximize space and storage:

Under the rear seats
Under the cargo area
Inside the spare wheel cover (bring extra lug bolts and good extendable lug wrench w/ proper size 17mm)
Inside the first aid cover

If you plan to sleep in the car, you can remove the other half of the rear seats to maximize space also. This also saves weight, which is replaceable with parts

IIRC the roof bars can hold 100kg from factory. If you plan to carry additional weight you need to reinforce it or use a supplementary roof rack system instead.

Study the weak points of potential break-away components and avoid touching those or make sure they are in good order. Or create a failsafe mechanism you can rely on to prevent them getting damaged. The radiator nipple going to the expansion tank, for example, is notorious for a handful of headaches where owners leaned on the said component and broke off the part, requiring a repair or a new radiator.

Before heading off, check the battery condition or replenish the water (if necessary). Bring some distilled water on your trip just in case and label it accordingly (you don't want to mix it up with potable water too).

In case you'll be driving into inclement weather (rain, etc), I would just be on the safe side and replace the wiper stalk and/or relay. I just replaced the said switch on my 300D because level I and II wiper function stopped. I thought it was the relay too, but now I've got a brand new wiper relay in case it fails also.

Remove what you plan to not use to save weight and keep things simple.

Four days to go, getting quite nervous! I have accumulated all the common-sense spares and some other goodies as recommended by this thread. Here are some pictures from the last two weeks...



I removed the rear seats for storage and to create the "sleeping cell". I will be going to Lowe's on Thursday and board it up, retrofitting the fresh water jerrycan, the shower canister and other odds and ends.



For maximum simplicity, I swapped all windows to manual. It was not hard to do, but unfortunately I did not have the time to create a DIY. Sorry!



New crank windows installed! I also rebuilt the instrument cluster, replaced the console plastic piece, glued a compass to the roof, installed a battery cutoff switch inside the glovebox and found a creative solution for my lack of A/C –a dash fan, just like a trucker!



Jacked-up Livingstone. It now sits a few inches taller at the rear (used a heavy duty factory W140 400SE springs); tomorrow it is getting twalgamuth's W123 rally spring kit.

__________________
[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine.

Duct tape and hose clamps with the right diameter sections 3-4 inch that match inner diameter of cooling hose so that you can patch a break - reinforce radiator upper outlet with copper tubing and expoxy (if not already done) 8 mm fuel hose with hose clamps can suffice if you break hard fuel lines -just leave hard plastic material on the nipple and fit rubber 8mm lines. Old school patch repair kit with a good compressor. Belts -change your belts with new and keep old belts. High lift jack and a "come along" i.e manual winch. Tape lens protector material over all headlights/fogs - Vac pump rebuild kit or spare vac pump - SLS high pressure hose -remember that the fittings are reuseable -you could always take a piece of the right hose precut in the right length. 80 amp glow relay fuse, box of nitrile gloves, fuel treatment perhaps . . . . enzyme, startron or other - One sealed container of MB coolant or Zerex G5, JB Weld! Amazing stuff - they have patched holes in tractor crankcases with the stuff, bring sandpaper and a file kit - Have a great time!

Love my seats btw, thanks for the great deal!

Nice! I'll take it you had to swap out the entire regulator correct?

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1982 300GD Carmine Red (DB3535) Cabriolet Parting Out
1990 300SEL Smoke Silver (Parting out)
1991 350SDL Blackberry Metallic (481)

"The thing is Bob, its not that I'm lazy...its that I just don't care."

Yes. Mercedes actually has pre-drilled holes in the door and the wooden door card itself, so there are no modifications at all. Perhaps the most you will have to do away from factory specs is to punch a little hole in the vinyl for the crank to go through!

__________________
[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine.

Hey, yer getting me nervous too! I guess, in a way, we're all going along with you in spirit.

Sounds to me like you are well prepared.

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Codifex
1981 240D ChinaBlue (Got her running with a donor engine.)
1983 300DTurbo w/sunroof.
1984 300TD manual sunroof. (Electrical Gremlins)

ZIP-TIES. Ideally, an assortment of several different sizes. Make sure to get ones with high tensile strength. I used these for the inevitable mishaps during my trip from Atlanta to Alaska a few years ago...

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-1985 300TD - 324k mi on chassis. MB "Tauschaggregat" 617 motor + 4-speed conversion
Alaska Roadtrip 2009
-2002 E320 Wagon - 197k mi
-1998 E320 Wagon - 310k mi - retired

Haha, thanks! I am trying to calm down by eating large amounts of chocolate, Chick-Fil.A peach shakes, and bacon concoctions. Tyler is quite impressed by all the bacon.

__________________
[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine.

I'm with you until the engine mounts. I'd put a new set in before departure. Do you really think you'll rip one on the road?

Starter is smart, but sealed bulbs? Common, no?

Why so many reverse lenses?

Are you really planning on doing a brake job on the road? Honestly on a car of this age, id install new calipers and brake lines all the way around before going. Then forget that stuff.

Don't see the need for the vc gaskets, but I'd definitely bring a replacement voltage regulator, not just the brushes.

I'd want a 3/8 and a 1/4 socket set, and a regular plus a t-handle schrewdriver (ratcheting), plus a breaker bar with a few sockets of relevant sizes.

Definitely fuel hose, vac line and couplings. What about radiator hoses? I'd replace before the trip, then maybe have a repair kit.

Tire plug kit with a bicycle pump would be smart.

I'd bring a clamp tomthenbattery terminals 12v socket as well as a clamp on ac inverter. A good deal of wire and a good wiring tool.

Fuel additive of your choice.

New tires and one on the spare.

Windshield repair kit.

Glass cleaner

2x6 board and some wheel chocks.

Radiator cap and drain plug

Change the at cooler lines to the armored type before leaving.

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Current Diesels:
1981 240D (73K)
1982 300CD (169k)
1985 190D (169k)
1991 350SD (116k)
1991 350SD (206k)
1991 300D (228k)
2008 ML320 CDI (199k)
1996 Dodge Ram CTD (442k)
1996 Dodge Ram CTD (267k)

Past Diesels:
1983 300D (228K), 1985 300D (233K), 1993 300D 2.5T (338k), 1993 300SD (291k)

Wow. Sounds like the trip of a lifetime!

I would say, in addition to your list:

1. A spare air filter
2. Fuel return line and tools to change same
3. Electrical repair kit - multimeter, wire strippers, wire, assorted connectors. Possibly even soldering supplies.
4. Lots of zip ties!
5. Gorilla Tape
6. Assorted hose clamps
7. Spare fusible link
8. fuel hose
9. Hard plastic vacuum line
10. Some dielectric grease
11. Engine oil, tranny fluid, gallon of 50/50 coolant and water
12. Can of diesel purge, and a plastic bottle with enough fuel line to be able to run diesel as an 'emergency' fuel supply!

All the best of luck!

PE

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83 240D - 4 speed manual - Manilla Beige
189K miles, Tachometer mod, cool wooden shift knob from PeachParts, CocoMats, Original factory paint, manual windows, manual sunroof. Starting to add AudioWrap to this car too!

Im not going to add anything to the "must have" list because it sounds like you have it pretty well covered, but I will say, be smart about every decision you make on the trip, double check and double think every move because you are going to be a LONG way from home and help. I wish you the best and will be following your journey as far as you go. Good Luck to you Miguel, and don't forget to give thanks for every bit of luck you have. I am truly jealous.

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Live simply so others can simply live



07 E350 sport Wife's Daily
01 E320 sport My Daily
00 C230 Kompressor Our back up (new Arrival)

87 300D Turbo my Daily for 8 yrs. Selling to neighbor

82 GMC Jimmy (K5) 6.2 Diesel (my Wheeler)
73 Roadrunner 340ci My very first car, still own it

With friends like you guys, my current health, and the relative freedom from most things that may tie me in life (wife, kids, mortgage) every day is a blessing! I am more than convinced that there is no better time for this trip than now. I have been working hard, selling most of my stuff, and I am extremely lucky to have some savings piled up to make an experience like this possible. The funny thing is that the average expenses of the freelance world traveler are SUBSTANTIALLY less than the average working Joe!

My engine mounts were replaced recently; my spare set was a present and doesn't hurt to have it with me!

Believe it or not, nope! It's Latin America. All W123's are Euro-spec!

The entire cooling system was replaced by the previous owner. Hoses will be the most common thing to find along the route, as ALL cars need them!

The W123 is a brilliant design, but one of the most blatant flaws in this car was to locate the reverse lights in a VERY vulnerable spot that cannot be protected easily. All of you snow drivers out there would agree, right? Cops –especially if corrupt and looking for trouble– will pick INSTANTLY on a broken lens.

Done by the previous owner. It is my understanding that I will need new pads about 1/2 - 3/4 through this trip because of all the mountain roads and stop-and-go traffic. The brake parts are light, cheap and specific enough to be worth taking with me.

Thanks for the wheel chock / 12V clamps / Windshield repair kit, those are REALLY smart suggestions!

__________________
[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine.

I would also strongly consider a satellite phone...

PE

__________________
83 240D - 4 speed manual - Manilla Beige
189K miles, Tachometer mod, cool wooden shift knob from PeachParts, CocoMats, Original factory paint, manual windows, manual sunroof. Starting to add AudioWrap to this car too!

Hello, PeachParts!

__________________
[GONE] - 1995 Mercedes E300 Diesel - 130k miles - Smoke Silver (702) over Mushroom leather (265) - Bladder blasting, coast-to-coast work machine.

I'm going to also throw in my $.02...

I spend from the mid 1970's thru the early 80's exploring/ surfing/ bumming around Central America. Over that time I drove from to and from Panama twice (from SoCal). The first time I had my Land Rover so crammed with spares that my girli and i could barely sleep in the back... And it still didn't help me when I "grenaded" my rear 3rd member.

Then 2nd drive down I took a Jeep and next to no spare parts because I learned that there are really good auto parts stores in just about every town of any size and dealerships of virtually every brand of vehicle in the capitols and major cities. So in the worst case scenario, You will have to leave you care in the trust of a mechanic and take the bus to the capitol to get parts, but more than likely you will be able to call them and have the parts put on the bus to your location!

It was not much of an issue 35 years ago! So, don't make it one now.

Make sure that you have VERY GOOD fuel filtration!!! Carry more than one extra primary filtration filter. Drain your h2o trap often! Also have a liter or 2 of fuel additive with you at all times. Bad fuel is going to be your #1 problem. One way to make sure this issue is minimized is to only fuel up where the semi's are filling up. Make sure that you have a full Jerry can with you at all times. Trust me you will end up in areas that are "waiting for the fuel truck to arrive.

You do know how to prime your fuel system, right?

The next big issue on making sure that you keep your drive line lubed (I'm not sure whether there are u-joints on your year wagon). If there are make sure you have spares.

make sure that you have a little strip of emery clothe to sand electrical connections. Corrosion is more than 90% of all electrical problems. Vaseline is good for coasting connections

It is also a good idea to mount you rear licence plate with a buttonhead Allen bolts so that it can't be stolen. Take of your front one and stash it in your car so that it the rear is taken... You have a spare.

Have you made "blackout" curtains for the wagon so that you can sleep on city streets without getting rousted? For that matter, keep all your possessions out of view with curtains or simply a tarp. Most theft in Latin America is "crime of convenience".

Do you have a hidden lock box securely mounted in the wagon for your valuables? If not, I'd delay your trip and get one welded up before you go!

Have fun and only eat in crowded & popular restaurants.