Big Bertha Gets a 5 Star Spa Treatment
Big Bertha is around ten years old now and, given the next leg of our journey will be in South America, where there is no MAN presence, we decided to treat BB to a top to bottom full service.
Choosing the right garage that would not treat BB as just another truck was not easy. However, I asked for recommendations on the South African MAN Truck Overlanding group and we were told that TM Trucking would be the best bet.
So we cautiously arrived at TM on 2nd August where we were immediately welcomed by Terry, owner and head gaffer. Although I had sent a list of things I wanted done in advance, after one look around the truck with Terry, that list got a whole lot longer.
Terry started his career at MAN – he was the first apprentice in South Africa and he worked mainly on the military vehicles. 38 years ago he left and started TM trucking. His venture has grown from a small shed to a full blown workshop to rival any MAN dealer we have visited.
Terry and his family were super hospitable. Terry allowed me to watch all the work being done (I learnt a lot about my truck), allowed us to stay in BB overnight and use the family’s shower and washing machine. Terry and his wife Lorna even hosted a BBQ with the entire workshop team towards the end of our visit.
For those interested, this is a list of the work we had done:
- Changed Engine Oil
- Changed Engine Oil Filter
- Adjusted Engine Valve and Exhaust Brake Tappets
- Repaired Radiator Cowling (bashed by a rock or something)
- Replaced Engine Belt Idler Gears (3) (known by Terry for failing)
- Replaced Air-conditioning Compressor Belt
- Replaced Air Compressor Belt
- Replaced Engine Rocker Cover Gasket
- Replaced Engine Rocker Cover / Injector Seals (3) (were leaking)
- Replaced Engine Injector Wire Harness Clip (broken)
- Replaced Main Engine Fuel Filter
- Inspected and Cleaned Engine Fuel Lift Pump Filter
- Replaced SEPAR Fuel Filter
- Removed, Cleaned & Reinstalled Radiator
- Removed, Cleaned & Reinstalled Engine Intercooler
- Removed, Cleaned & Reinstalled Air-conditioning Condenser
- Removed, Inspected and Cleaned Alternator (brushes are 1/3 worn)
- Regassed Air-conditioning
- Replaced Engine Cooling Fluid
- Replaced Flywheel Ring Gear
- Replaced Starter Motor
- Inspected Air Compressor and Fitted New Gaskets
- Replaced Front Engine Mountings (old ones completely broken)
- Changed Engine Air Filter
- Repaired Small Crack in Exhaust Pipe
- Removed, Cleaned & Reinstalled Gearbox
- Replaced Gearbox Gearshift Module (reconditioned unit)
- Replaced Clutch Fork End Bearings (used)
- Fitted New Clutch Plate, Pressure Plate and Thrust Bearing
- Changed Gearbox Oil
- Changed Transfer Case Oil
- Replaced Transfer Case Input Seal
- Replaced Transfer Case Front Output Seal
- Replaced Rear Differential Seal and Nut
- Replaced Rear Axle Oil
- Replaced Rear Axle Planetary Gear Oil
- Replaced Front Axle Oil
- Replaced Front Axle Planetary Gear Oil
- Replaced Front Axle Knuckle Oil (upper only)
- Replaced Front PAX Kingpin Upper Seal
- Uploaded New Version of TCU Software (328-SAP) to Gearbox
- Replaced Front Shock Absorbers (right hand side shock completely shot and probably why we broke a leaf spring)
- Replaced Front Anti-Roll Bar Bushes (4)
- Replaced Front Right Leaf Spring (broke supporting leaf in Zimabwee)
- Checked and Adjusted Wheel Alignment
- Calibrated Rear Suspension Ride Height
- Fitted Additional Air Tank (ready for TyFlate system)
- Replaced Air Dryer Cartridge
- Replaced Windscreen (cracked in 2019 in Namibia)
- Fitted Air Horns
- Replaced Broken Head Light Grill Clips
- Repaired Rear Tyre Rack Securing Mechanism
- Replaced Front Brake Pads
- Replaced Rear Brake Pads
- Replaced Position Lights With Covers (fed up of trees breaking them)
- Fitted New Cab Shocks – Front and Back
- Removed and Inspected Rear Shock Absorbers (ok)
- Cleaned Chassis (is in good condition)
- Inspect Drag Link Ball Joint Rubber (still ok)
- Topped Up Power Steering Fluid & Inspected Filter (ok)
- Replaced Cab Pollen Filter
- Inspected Rear Antiroll Bar and Axle Bushes (ok)
- Repaired Right Door Lock
- Installed New Front Step Clip
- Installed Front Side Step Rubbers
- Fitted New Tyres (6 x ZXL 365/80/R20)
- Washed Cab and Cabin
Big Bertha now drives really well and is ready for South America! Thank you Terry and Crew.
UPDATE March 2023
We returned to Terry’s workshop in March for some last minute jobs before heading to Durban and our journey to South America.
This is a list of the work we had done:
- Replaced Windscreen (stone chip 3 weeks after last new windscreen!)
- Replaced Engine Rocker Cover / Injector Seals (3) (were leaking)
- Replaced Engine Injector Wire Harness Clip (broken)
- Replaced Starter Motor
- Tightened Cooling Union (loose and leaking)
- Blew Out Air Filter
- De-rusted and Painted Cab Doors
- Rotated Tyres
- Replaced Steering Drag Arm Ball Joint Rubbers
- Fitted One Way Air Valve to Aux Air Tank
- Dissembled, Cleaned and Reassembled Air Drier Purge Valve
Enjoy South America
so you are prepared for south america. you remember we did south america from january 2015 until covid19 took us home just in a sprinter van, no 4×4. we left a lot of entries on i-overlander.
so enjoy your time – we loved the continent!
We will follow in your Ioverlander footsteps!
17 new heads and 14 new handles?? 🙂
Thank you Trigger!
Hi again Overlanders,
After almost 3 yr – with some interruptions – leaving the African continent….. very impressive. South America… and assuming North America years later. 2026 I plan to retire and perhaps you are around Seattle by this time?????
Wish you a great and safe start for the journey through the Americas.
Robert
Hi Robert, we will be sure to call you when we arrive in Seattle. Hi to Rachael. Dave
That is a looong list. What luck to find the right workshop. You **might** be lucky that some parts from the Brazilian VOLKSWAGEN trucks are interchangeable. After all, VW owns MAN (and Scania). We found with our Mercedes NG that often smaller bits and pieces, like seals for brake cylinders, are standard sizes and don’t need to have the company logo and numbers on them.
Enjoy South America and don’t leave out Brazil, it’s despite all its problems are very welcoming country, just too large to fully do it justice!
It was an expensive list. But who said overlanding was cheap? Its stuff like a windscreen that would be a problem!
Just a few things then ? Ha ha !
All the best for South America,
Happy 10th birthday to big Bertha 🎉
May there be many more.
BB has a new lease of life!!
Big Bertha is amazing! We were surprised that more major repairs weren’t needed after hammering along on African roads or maybe the roads have improved since we were there.
The photos of the South African scenery are awesome- such vast expanses of wild beauty.
Thanks for a great blog.
Enjoy South America.