Honda Pilot TLC Build for Trail & Overland Use

[aggrex]

Pilot has been taken off-line and parked in the garage for a summer build project. There will be some general repairs and some minor modifications to make it more trail worthy. It won't be a fast build but the thread will be updated regularly. Most of the parts have arrived but the exhaust system is an issue as the OEM front pipe has been backordered or discontinued. Inspired by some of the hard-to-find Pilot builds on Overland Bound, i.e. @b0wfin , @Jostr and others.
ReadyLift 2"/1" lift kit
HRG sub-frame spacer kit
Denso radiator
Derale auxiliary trans cooler
Moog springs
KYB strut/shock
S-Tech relay switch

 

[aggrex]

Exhaust system needed work right away and the selection was limited as the OEM front pipe was discontinued or on backorder. Replacement exhaust choices were Walker or Bosal. I remember as a child the TV commercials promoting Meineke mufflers as a place to go. PSA: avoid Meinke mufflers whenever possible. Check out some pics of the half-ass repairs to the flex section of my front pipe. Too lazy to do the job correctly and the use of pipe cement to seal the massive leak. Inspection mirror shows the poor half-ass welding. Bosal markets an affordable front pipe thats way better than the Meineke repair.

 

[aggrex]

Unlike lifting full-framed vehicles, lifting uni-body vehicles with CV axles can affect long-term durability and increased stress on the drivetrain and CV axles due to changes in axle angles. One option is the military green colored HRG sub-frame spacer kit which will help keep CV axle angles closer to stock reducing excess wear or vibrations. New Moog springs and KYB shocks.

 

[aggrex]

Needed to find an ideal spot for auxiliary switches in the Pilot without major alterations of the dash. Decided on the empty spot to the left of the steering wheel.The relay-switch box controls SIX 12V accessory items and installation is super easy. Only one bundled cable enters the Pilot and all 12V connections are made under the hood.

 

[aggrex]

Liking the new ”air space” which will be even higher with some 31s. No lifting needed for oil changes.

 

[Jostr]

The builds looking good, thanks for the shout out.

 

[b0wfin]

Your Pilot looks super clean! Keep up the great work!

 

[Eddiebrs]

As a pilot owner, I say great work!

 

[itsscottwilder]

So just so I'm understanding, you did a lift kit AND then did the spacers?

 

[dsd8357]

I like where this build is going - your thread & the builds of @b0wfin and @Jostr inspired me to join! We might not bias our Pilot so much for off-road/overlanding, but I like the inspiration that your (all) builds provide.

I had a question about ride height BEFORE suspension lift. My ground-to-wheelarch distance is 32-1/2" front and 31-3/4" rear. The spacer-type lift kits that quote ~2.5" front & ~1.5" rear seem like they'd bias a Pilot nose-up (especially if cargo weight is mostly added to the back). Were your pre-lift measurements close to this? Thanks!

 

[Jostr]

I like where this build is going - your thread & the builds of @b0wfin and @Jostr inspired me to join! We might not bias our Pilot so much for off-road/overlanding, but I like the inspiration that your (all) builds provide.

I had a question about ride height BEFORE suspension lift. My ground-to-wheelwell distance is 32-1/2" front and 31-3/4" rear. The spacer-type lift kits that quote ~2.5" front & ~1.5" rear seem like they'd bias a Pilot nose-up (especially if cargo weight is mostly added to the back). Were your pre-lift measurements close to this? Thanks!

With the ebay special kit put on mine it was 2.5 front and rear. I disconnected both front an rear sway bars and the weight transfer on road was quite a bit. As far as nose up mine set level empty. 250 lbs in gear and spare tire hanging off the rear she would sag pretty good in the back. Air bags are your friend or replace with new springs.

 

[dsd8357]

With the ebay special kit put on mine it was 2.5 front and rear. I disconnected both front an rear sway bars and the weight transfer on road was quite a bit. As far as nose up mine set level empty. 250 lbs in gear and spare tire hanging off the rear she would sag pretty good in the back. Air bags are your friend or replace with new springs.

Thanks for the quick reply! I might not need to go for that much lift, just +1" in back from stock (where it is now) would level things out when we're all loaded up. Maybe the rear springs have settled from stock ride height.

 

[aggrex]

So just so I'm understanding, you did a lift kit AND then did the spacers?

Following guidance from HRG who stated installing the sub-frame spacer kit first makes the lift kit installation easier. That tip from HRG was accurate and makes a lot of sense on uni-body sub-frame strut suspensions.

 

[aggrex]

I had a question about ride height BEFORE suspension lift. My ground-to-wheelarch distance is 32-1/2" front and 31-3/4" rear. The spacer-type lift kits that quote ~2.5" front & ~1.5" rear seem like they'd bias a Pilot nose-up (especially if cargo weight is mostly added to the back). Were your pre-lift measurements close to this? Thanks!

My Pilot measurements were similar to your measurements. With stock tire size the lift kit and sub-frame spacers bumped me to FRT 34 1/2" and RR 35" from ground to bottom of the fender. I expect the new springs to settle some over time. If the Pilot sags from cargo loads consider air bags within the rear coils.

 

[dsd8357]

My Pilot measurements were similar to your measurements. With stock tire size the lift kit and sub-frame spacers bumped me to FRT 34 1/2" and RR 35" from ground to bottom of the fender. I expect the new springs to settle some over time. If the Pilot sags from cargo loads consider air bags within the rear coils.

Thanks for that measurement & confirmation! So the eBay kit & rear air bags may be the way to go. If I could just do the rear kit and get ~1" add. ride height that might be sufficient. I'll start looking at tire options as well - seems like you all go 245/75r16. Our Pilot has been so reliable, and only 180k miles, so it's great to think about expanding its capabilities. Thanks again!

 

[aggrex]

Made an addition to the Pilot to improve night time or dark garage visibility under the hood. Installation was modified by installing rivet nutserts into the hood to bolt the KC lights onto the hood. Just need to tidy up the wiring.

 

[aggrex]

The KC lights were strategically mounted to place maximum light over the engine when the hood is opened. The wires were wrapped then tucked into the hood. The KC lights won't be able to double as rock lights but that was not the intent for this installation.

 

[aggrex]

Replaced the leaky radiator, thermostat, hoses, OEM PS cooler, PS metal return line and ATF lines. Upgraded the Pilot with auxiliary PS and ATF coolers in line with OEM coolers. Ordered OEM style hose clamps for PS, ATF radiator hoses. The OEM style hose clamps are spendy but are much better than the typical worm drive clamps. Used 3/4” x 3/4” aluminum square tubing for the ATF cooler and 1/2” x 1/2” for the PS cooler. After struggling with rusty broken bolts and nuts for weeks I used stainless steel fasteners to avoid future rust issues.

 

[aggrex]

Oops teaser pic

 

[aggrex]