How to Pack a Traveling Tool Kit for Overlanding and Off Roading
If you’re planning to travel for any length of time in your vehicle, especially while off roading or overlanding, having a well thought out traveling tool kit is critical to ensuring you have the means to make necessary repairs to your vehicle when needed.
So in this guide we’ve outlined how to make your own overlanding or off roading tool kit, as well as a complete list of contents and tools you can include to help ensure you’re prepared for any mechanical issue your adventure may throw at you.
*(This post contains affiliate links. This means we may receive a small commission, at no additional cost to you, if you make a purchase through a link. See our full disclosure.)
General Mechanics Tools for Your Traveling Tool Kit
These are the most commonly used tools to include in your overland or off roading tool kit, and will tackle the majority of basic trail repairs and mechanical service on your vehicle.
Combination Wrenches - a quality set of flank drive style ratcheting combination wrenches - like this awesome flex-head set from Tekton* - will greatly reduce the likelihood of rounding off fasteners on your vehicle
Breaker Bar - you’ll want an at least 18” long, ½ inch drive, ratcheting or fixed breaker bar on hand for tackling wheel lug nuts and freeing other high torque fasteners
Ratchets & Sockets - a ¼” drive, a ⅜” drive, and a ½” drive ratchet should be included in your traveling tool kit. If you’re looking for a starter set, Tekton makes excellent quality ratchet and socket sets* at very reasonable prices; they include flank drive style sockets and are made in the U.S.A.
Long Ratchet Extensions - handy for very narrow or difficult to reach bolts and fasteners
Torque Wrench (or torque adapter* to save space)
Small Ball Pein Hammer and Large 3lb Hammer
Pry Bar (angled tip) - this set of Tekton pry bars* is the one we use and includes a 12in., 17in., and 25in. with strike plates. We usually only carry the 17in. in our overland tool kit.
Various Pliers:
Standard Slip Joint*
Large Groove Joint*
Vice Grips
Screwdriver Set - using a variable bit screwdriver* can help save space in your tool kit; we also recommend carrying a large and standard size flathead screwdriver as well.
Allen Wrenches or an Allen Socket Set* - (carry metric or standard as applicable to your overland vehicle)
Hacksaw - a mini handheld hacksaw* will save space in your traveling tool kit and has a TON of uses
Punches, Chisels, Brass Drifts, Spare Hacksaw Blades
Small Pipe Wrench
Feeler Gauges* and Spark Plug Gap Tool
Spark Plug Socket
Gasket Seal Puller*
Ball Joint/Tie-rod Separator* - for front end service work
Grease Gun - we carry a mini grease gun* with a long flexible hose* and a LockNlube needle fitting* in our traveling tool kit to save space and ensure we can easily service tight or hard to reach fittings
Timing Light w/ RPM Gauge - this can be very handy for setting timing and adjusting carbs on older vehicles
OBDII Bluetooth Scanner - allows for all kinds of real-time engine data and diagnostic information on vehicles equipped with an OBDII port, we personally use and recommend the OBD2Link MX+*
Electrical Service Tools for Your Traveling Tool Kit
Keeping a basic set of electrical service tools in your travel tool kit can help with diagnosing and repairing most electrical issues you may encounter on your adventures. We recommend including the following in your off road tool kit:
Multimeter - here’s how to use the multimeter in your traveling tool kit for testing and diagnosing issues with your vehicle’s electrical system
Wire stripper/crimper - the Irwin Vise-Grip self-adjusting wire stripper* is fast and easy to use for automotive applications
Various sizes of wire splices, butt connectors, ring terminals, and wire nuts
Electrical tape
Heat shrink tubing
Zip ties
A small jumper set with alligator clips for diagnostics
A variety of spare vehicle fuses
We opted to compile our electrical service kit using components and tools we already had on hand, but this WORKPRO 582-piece electrical kit* is a great setup to start with.
Tire Repair Kit for Your Traveling Tool Kit
A good tire repair kit is worth its weight in gold when needed on the trail. We use and recommend keeping the ARB Speedy Seal* in your overlanding or off road tool kit. This tire repair kit includes:
A carry case
Pliers - for removing the object imbedded in the tire
Repair Cords - used to plug tire punctures
Tire Reamer - used for cleaning and expanding the puncture for repair
Insertion Tool - used to insert the repair cords into the puncture
Lubricant - for the tire reamer
Blade - for cutting the repair cords once inserted into the puncture
Allen Key - to adjust the reamer and insertion tools
Valve Accessories - for making valve stem repairs
A Tire Pressure Gauge - to ensure the repair was successful
Here’s a quick video on how to use the kit to make tire repairs:
In addition to a tire repair kit, we highly recommend carrying a 12v compressor* or CO2 tank*. You’ll need this for both reinflating your tires after an air down for off road driving, as well as for airing up tires after a repair. Check out our complete guide on How to Air Down Tires for Off-Road Driving and Overlanding for a variety of ways to air up and air down your tires.
Misc Tools & Equipment to Include in Your Off Road Tool Kit
These are various tools and items that are good to keep on hand, either in your vehicle or your travel tool kit, while traveling off road or overlanding.
Spare Vehicle Fluids - keep extra engine oil, gear oil, ATF (automatic transmission fluid), and anti-freeze (or distilled water in warm climates) on hand to replace in the event of leaks or if draining fluid is required for repairs
A small Automotive Funnel*
Variety of spare hose clamps*
Assorted heavy-duty zip ties
Jumper Cables - not all jumper cables are created equal and a high quality set, like this 2 gauge jumper cable set made by Spartan Power*, is a worthwhile investment - especially for trail welding
Steel baling wire* - great for a number of things, including holding parts (e.g., brake calipers) out of the way while making repairs
Duct tape and plumbers tape
Welding electrodes, short 4 gauge jumper with battery terminal adapters, and welding goggles* - used as a kit for an emergency trail welding repair using two 12v batteries and jumper cables
Bottle Jack - we prefer mechanical bottle jacks (like those found in older Toyota Pickups and Landcruisers) over other hydraulic variants that can leak if not stored properly
Secondary Recovery Jack - you can check out our Complete Guide to Off Road Jacks for an in-depth look at the various jack options you can carry. However, the classic Hi-Lift Jack*, outside of an its primary function as a vehicle jack while off roading, can also double as a vice or press for mechanical repairs.
Factory Service Manual
You can have all the tools in the world in your travel tool kit, but without the knowledge of how to use them when needed, they will be little more than extra weight in your vehicle.
That’s why carrying a Factory Service Manual for your specific make, model, and year of overland vehicle is arguably one of the most valuable tools to keep with your overland tool kit. This is the manual used by factory service technicians and provides extremely detailed step-by-step instruction and diagrams of every repair and component on your vehicle.
They can be pricey and sometimes difficult to source depending on the vehicle, but, when needed, they are worth their weight in gold!
Specialty Service Tools
Each vehicle will often have specialty service tools that are specific to that make, model, or drivetrain. There are also tools like a compression tester* that can help with mechanical diagnostics. Depending on your mechanical abilities and the extent of DIY service you intend to tackle (or be prepared to tackle) while traveling, you may or may not want to carry these items in your travel tool kit.
There are often “work arounds” using more standard tools, however these specialty service tools can make certain jobs significantly easier if you have them on hand. Examples would be: a harmonic balancer removal tool, valve shim removal tool, 54mm socket for axle service on old toyota 4x4s, etc. Reviewing your vehicle’s Factory Service Manual can give you insight into what specialty tools may be handy to add to your overlanding tool kit.
Organizing Your Traveling Tool Kit for Off Roading and Overlanding
Having a well organized travel tool kit and knowing exactly where your tools are stored in your kit can make repairs SO much easier. There are thousands of tool bags and tool rolls on the market, but here are three budget-friendly options that will help keep your off road tool kit organized.
Rover Tool Roll
This tool roll has five large 14” wide main pockets with labels to help keep everything separated and organized. It’s also made with durable heavy duty cotton canvas.
Gary Tactical Wrench Roll
This tool roll is another great budget-friendly option for keeping things organized, with multiple storage slots for wrenches and pliers, as well as several storage compartments for bulkier tools.
Rothco Tool Bag
We’ve used these rugged and inexpensive Rothco tool bags for years to keep our travel tool kit contained. This one measures 19 in. x 9in. x 6in. so it can easily accommodate longer items like large groove-joint pliers, a pry bar, and other awkwardly-shaped specialty tools.
IMPORTANT: Your traveling tool kit doesn’t need to include everything in this list!
You can start with a basic off road tool kit that only includes the tools you know how to use, then begin adding more tools to your kit as your knowledge, experience, and mechanical skills improve.
Having a good emergency communications setup for off roading or overlanding, so you can reach out for help if needed, can provide peace of mind in the event you don’t have the skills or tools in your tool kit to make the necessary repair. Check out our guide to Overland Off Road Radios and Emergency Communication Devices for help selecting a comms setup for your adventures.
We do hope this guide helps you be prepared for your off road and overland adventures, and if there’s an item you think is valuable to include be sure to drop a comment down below!
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As always, thanks for reading!
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