DirtyComanche

It depends on tire size. And yeah, you don't want zero for anything that goes faster than about 15mph. 1/16" is a minimum, 1/8" is great. On larger tires (37"+) 1/4" is a better number to go for, especially if you have minimal caster and can't add any; you're sacrificing some tread life for actually being able to keep it on the road. He's got lots of caster... So anywhere between 1/16" and 1/8" will be fine.

You'll get away reusing the driveshaft, the trannies are basically the same length. As to the tcase, you can shift it on the bench and spin the input/outputs to make sure it engages/disengages the front output and will go into low range, and that nothing hangs up while spinning it. Beyond that you can only really check to see if the outputs are obviously loose or the seals worn out. If you suspect it you might be best off to just order a chain and seals, then pop it apart and see if any of the bearings look or feel bad.

My S10 cap is close enough you'd never really know it isn't meant for a MJ... Unless you really look, then you can see the taper is wrong and the angle at the back of the cab isn't quite right, but for an aftermarket piece it's normal for fitment to not be 100% bang on.

I'd look at converting to cables, personally.

That's an interesting story about your family. I definitely recommend you take time to do the trip at some point. There's some more interesting places that we didn't hit, but I planned this to be a pretty quick tour. It would have been mid afternoon on the 7th, if I have my dates right.

Go to a spring shop and have them make a set of 9/16" ubolts.

Maybe in AZ... In the winter I'm often wishing I changed the door seals to help keep the heat in.

100% accurate.

They're torque to yield, no go on reusing them. Basically they stretch out permanently each time you torque them, and they're only meant to do that once. I had a ubolt break and just about kill me in the ensuing chaos. I ranked the experience as about a 0/10.

I recommend it if you have some time. I decided not to go to Banff, since it was farther south than I wanted to go, but if you're coming up it's a great place to go too. It more or less did. I need to find a fan shroud and AUX fan because I'm disappointed that I couldn't do the Canoe Mountain trail. The dead speedo is annoying, I think the cable snapped internally but I'll pull it apart to see at some point. There's some other things that were on the list of stuff to fix before that might have moved up in priority now... The funny thing is that stretch of highway really isn't a big deal compared with lots of highway in BC, certainly not in the summer. I didn't take any pictures there because I've driven it so many times. Do it while you can! There was one slightly boneheaded cop maneuver on highway 5. They had a speed trap on the bottom end of the snowshed. I thought there might be and was going pretty slow, but basically as you got out of the snowshed and faced the blinding sun they were there, so lots of slamming on the brakes and likelihood of fender benders.

So, according to Google that's 2580km. But I could not add in all the side trips, and like I said the odometer (and speedometer) failed in Valemount, so who knows.

Last day was a cannonball run back home. 632km of winding roads and scorching heat. I didn't take many pictures because I mostly just drove. Leaving the Tantalus One of the few lookouts on Hwy 99/Duffy Lake Road, it's too narrow in most places for there to be anywhere to pull out. Last stop for gas and snacks in Quesnel

Next day was minimal driving. I'd actually planned to drive to Cache Creek after spending time at Whistler, but is was easier to stay. First stop was Brandywine Falls. It's a very short hike from the highway and does not disappoint. From there it was to Whistler, and the Gondola to the top. Quite the view from up there

Forgot to put the map in the last one... Then it was off to Cathedral Grove. There's some more old trees here. Unfortunately the sheer number of visitors is starting to show on some of them. And back to Nanaimo to grab the ferry to Horseshoe Bay And here we are staying at a decent place in Squamish... They had an underground parking garage so I could be assured the MJ would not go missing in the night even.

The next day was another big travel day, although it's under 300km on the odometer... Which broke back at Valemount actually, so I really had no idea how many km I logged on the trip. Up the Malahat Highway: First stop was the Forestry Discovery Center in Duncan. When I was a kid they would run the Shay around, I didn't find anyone that knew but I'm guessing the boiler needs to be redone on it and they don't have the money. The Climax (right) looks complete, but I'm guessing needs a lot of work. View from the lookout tower. They were using the little diesel that day, but they have a little tank engine they run on the weekends now. Found an old Austin-Western grader. These were well ahead of their time with all hydraulic controls when most things were linkages and wheels. LeTourneau loaders and stuff If you're ever near Duncan, do stop in here, lots of neat stuff and admission is fairly cheap.

Then it was a short trip to the ferry terminal and over to Victoria. Hit up the Inner Harbour. The Provincial Capital Building in the background. Popped over to Butchart Gardens as it is an impressive sight. Sunken Garden, this used to be a completely barren limestone quarry. Parts of the Japanese Garden

Then it was a 440km leg to Vancouver. We made one stop at Bridal Veil Falls, as it's just off the highway and a good place to take some pictures while stretching your legs. From there we parked the truck and went downtown.

From there it was a quick 300km to Vernon. Dinner at The Island Restaurant in Golden: Somewhere along Hwy 1: Had brunch in Revelstoke. It's pretty hippy there. I took no pictures of Vernon because it's Vernon. Sorry for people that like Vernon.

Of course we stopped at Lake Louise, as it is probably one of the most iconic places in the Canadian Rockies. We also did an side trip to Takakkaw Falls in Yoho National Park, this is about 40km out of the way, bringing the total for the day to about 400km. It's well worth the trip, as it's a spectacular waterfall and not too busy as it is a long winding road to get there. Unfortunately apparently I'm allowed 97mb~ of images total, so just blew that out of the water... Imgur hosted from here.

Next up was the drive to Golden, just a hair over 300km on the Icefields Parkway. This route is scenic, to say the least, pictures will never do it justice.

I forgot to mention, we stayed at the Sawridge in Jasper. I'm suspecting some people were questioning why I was driving a truck that appeared to be worth less than the room cost for the night. There's also a cool old steam engine in the middle of town. And we stopped in at Gogmorgo's place and I bought a steering column off him.

The next morning we took the gondola up Marmot (or whatever it technically is) to get a view. Weather was not optimal, but it was still an interesting sight. From there we headed south, and stopped at Athabasca Falls. It's right by the road and well worth a look.

Medicine Lake (on the way to Maligne Lake) and Maligne Lake.

The next day it was off to Jasper, and Maligne Lake. I'd never actually been to Maligne Lake, but it was a good little side trip. Unfortunately the day was hazy, so it was not the best for photos. On the way we stopped at Mt Robson Park. Mt Robson is the highest point of the Canadian Rockies. We just went to the trailhead to get some pictures. And we stopped at Moose Lake for some pictures.

Just before Valemount, if you know where to turn, you can take the old road. The bridge is much more interesting than the concrete monstrosity of the actual highway, and the Fraser river is a very nice colour at this point as it is entirely glacial fed. After having dinner in Valemount, we tried to climb Canoe Mountain. I have done this trip before, and the view is incredible as you wind up on a cliff face well above tree line. Alas the Comanche was not interested, too hot of a day, too much grade, and I didn't want to risk hurting the engine. Only a few more switchbacks and we would have been to the treeline, but I put tail between legs and let her cool down and turned around. Somewhere I have pictures of my previous trip there... I should try to find them.