Ultimate Nissan Patrol Overland Build – a Y60 on 35-inch Tires

Times change and vehicle manufacturers come up with new models, but a Nissan Patrol Y60 still remains a gold standard of an overland vehicle platform, especially in Australia. Its coil-sprung live axles at both ends, a cast-iron TD42 diesel that eats miles, and a super durable body-on-frame chassis are the key reasons why.

This 1992 Patrol GQ from New South Wales, Australia might be the most complete overland build we’ve ever featured. Riding on 35-inch Nitto Trail Grapplers, breathing through a Garrett GT3076 at 36 psi, and carrying countless pieces of expedition equipment, gear and everything else one may need to cross the wildest territories safely.

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I got in touch with Chris Serone, the owner of this white Y60 to talk about this rig. I already knew it’s remarkable, but the deeper I dug into his parts list, the more impressed I got. Nearly every system on it has been rebuilt, re-engineered, or fabricated from scratch, from widened GU axles and King remote-reservoir shocks to a false-floor storage system and an electric clamshell rooftop tent. Let me walk you through how it all works together!

Category	Details
Engine	4.2L TD42 Diesel (GU Internals)
Aspiration	Garrett GT3076 Turbo (~36 psi)
Suspension	5-inch lift, King 2.5-inch remote reservoir
Axles	Widened GU (Y61) with braced housings
Tires	315/75R16 Nitto Trail Grapplers (35-inch)
Fuel Capacity	168 Liters Total

The Build

The Patrol Y60 (sold as the GQ in Australia) is a full-size, body-on-frame 4×4 with a part-time 4WD system, a dual-range transfer case, and coil-sprung solid axles both front and rear (the late 80s-early 90s competitors of this model typically had leaf springs, and simply couldn’t match the Patrol in terms of articulation).

It came with 30-31 inch tires, about 8 inches of ground clearance, and a rear LSD from the factory, which, based on our stock off-road vehicle capability rating, gained 64.3 out of 100 points possible.

Like anything on this planet, the Y60 Patrol is not perfect and does have some (relatively) weak points, like axle housings that bend under sustained heavy loads, and low torque on the naturally aspirated TD42 diesel (even though indestructible) once the truck is loaded for big adventure.

With a goal of preparing this Patrol for long-range overlanding, Chris has mitigated all of its weak points with custom upgrades and modifications to get a solid and reliable base for challenging outback tracks.

Wheels & Tires

This Y60 Patrol sits on a set of stock heavy-duty 16×8-inch steel wheels at a -22 offset, and they are here for a reason. The logic behind steel is purely survival-based – a bent steel wheel can be hammered to seat back into shape, reseat the tire, and keep driving, whereas a custom rim can crack or get irreparable damage. The aggressive -22 offset pushes the mounting face deep into the barrel, widening the track to claw back the side-hill stability lost due to the 5-inch lift.

Wrapped around those steelies are 315/75R16 Nitto Trail Grappler mud-terrains (a true 35-inch tire) which is a major step up from the ~30.6-inch factory that gives another 2 inches of height under the axles. A truly tall tire side profile provides lots of room for airing down and improving the surface contact patch. That’s why running 12-15 PSI is not a problem on this setup.

The trade-offs are real – 82 pounds of rotating mass per corner, which takes a toll on brakes, gearing, and fuel economy – but every one of those downstream effects has been addressed further in the build.

Suspension

Lifting a live-axle vehicle (and pretty much any vehicle) five inches significantly changes the factory geometry if not done correctly. Without correction, caster approaches zero and the steering turns vague and wandering at highway speed. The fixed-length factory panhard rods inevitably pull both axles off-center.

Chris corrected all of it with Superior Engineering chromoly adjustable panhard rods that perfectly recenter the axles, plus upgraded radius links that restore proper caster and bring back factory-like steering movement.

Cushy damping is where this build separates itself from the average lifted Patrol. Standard shocks hold a small volume of oil that foams and boils over hundreds of kilometers of corrugations, producing “shock fade” and a total loss of damping.

The new King 2.5-inch smooth-body adjustable shocks installed here come with remote reservoirs that exponentially increase their oil capacity and cooling.

The trick with overland SUVs that carry a ton of equipment above the rear axles is adjustability, and Chris decided to address this with Airbag Man helper airbags. They level up the rear and ensure optimal suspension damping no matter if the truck is loaded or not (when the water and fuel tanks are full, he inflates the bags to level the chassis; once camp is set and the tanks are empty, he deflates them for a normal ride).

Drivetrain & Axles

The axle housings of the Y60 are known for slight bending, or “smiling,” as Patrol owners call it. Under the static weight of steel armor, 168 liters of fuel, and touring gear they just deform.

The factory track width also feels narrow once the center of gravity goes up, making the Patrol feel a bit tippy. Though, Chris solved both problems at once by swapping the Y60 axles for wider units from a later Y61 (GU) Patrol, instantly increasing track width and durability. Before installation, both GU housings were fully braced and fitted with weld-on bash guards to resist deflection under heavy impacts.

Inside the housings, the drivetrain is optimized for the rotating mass of the 35s by switching to 4.6 differential gears. It also keeps the TD42 in its optimal powerband instead of lugging below boost at lower RPMs.

Another cool upgrade is the front automatic locker, which, paired with a tightly shimmed rear limited-slip differential, boosts the off-road capabilities of this vehicle to the absolute maximum.

DBA kangaroo-paw slotted rotors and rebuilt TB48 twin-piston calipers are responsible for stopping this outback train safely.

Engine & Performance – TD42 at 36 psi

The factory cast-iron TD42 4.2L inline-six diesel engine has a legendary durability, but in the naturally aspirated version it simply lacks the torque to move a fully loaded overland rig. To address this, Chris has rebuilt the silver-top TD42 with GU turbo internals, then pushed it to a reliable 36 psi of boost with a Garrett GT3076 turbocharger.

Unlike older journal-bearing turbos, the GT3076’s ball-bearing center cartridge spools early, delivering critical low-end torque for off-roading while flowing enough CFM to avoid exhaust backpressure at highway speed (3.5-inch stainless straight-pipe exhaust also helps with that).

Though forcing that much air into the cylinders wouldn’t give results without a mechanically timed 12mm high-flow pump paired with larger, pop-tested injectors that keep the ideal air-fuel ratio at full boost.

Compressing intake air to 36 psi generates massive thermal loads, so a front-mount PWR intercooler – fed through a custom-shaved grille with custom piping – drops intake air temperatures before the manifold.

Keeping the IATs low is the single most effective way to manage EGTs during long, sustained loads like dragging a three-ton Patrol through deep sand.

The intake air enters through a 4-inch stainless snorkel and a Patrol Doctor high-flow airbox. A larger alloy radiator keeps coolant temperatures in check.

To get the range Chris wanted to cover, it was required to improve the fuel capacity (gas stations are often a rarity in places he travels to), so it was decided to install a 90-liter primary tank plus a 78-liter Brown Davis auxiliary sub-tank, holding about 168 liters of diesel.

Exterior Modifications – Armor & Utility

For the Australian outback, and off-roading in general, body armor is basically a survival mechanism, which is why Chris has fitted his Patrol with a custom steel front bumper with integrated 9,500 lb winch, lights and quick connects to air, hot water (plumbed from an engine-bay heat exchanger for showers), and an Anderson plug for jumper cables or solar input. In addition to these overlander-friendly features, it also maximizes the approach angle and helps to clear oversized 35-inch tires.

The rear bumper does the same thing but also carries the full-size spare tyre + gear/laundry bag on the dual-pivot swing-away mechanism (hanging a 35-inch spare on the factory barn doors would inevitably shear the hinges).

Even the dual GME antennas earn their keep – mounted on folding brackets, one is cut to the exact height of the roof rack, acting as an audible feeler gauge for low branches and car parks.

On each side of the Patrol you will find heavy-duty chassis-mounted rock sliders that can support the three-ton weight if it drops onto a ledge.

Rounding out the exterior is a custom-built roof rack and the 2.5mm aluminum kitchen box. It has a slide-out cooking station with stove, Jetboil, dry food storage, USB charging, and dimmable LED strips, backed by a 34-liter gravity-fed water tank and gas bottle storage – an absolute dream setup for any overland expedition.

Overland Upgrades – The 5-Minute Camp

On a multi-day off-road trip, the speed of camp setup is what defines the quality of life after eight hours of brutal driving, which is why all the gear installed here was chosen specifically to eliminate the setup friction.

Instead of a soft-shell tent (in the version 1 of the build) with covers to unzip and window rods to insert, the roof carries a Bundutec Bundutop electric clamshell rooftop tent.

Even though pricier and a little heavier, with a press of a button, an internal winch raises the tent in seconds, and the 130W flexible solar panel on top is already soaking up sun. Inside, an ExPed Megamat Duo self-inflating mattress makes it a pretty comfortable bedroom.

Weather protection is ensured by the 270-degree Foxwing awning wrapping around the kitchen side of the truck – and crucially, it’s supported by Super Peg spigot poles rather than guy-lines. In the rocky, sun-baked soil of the outback, where hammering tent pegs is quite the task, a freestanding awning is a massive tactical advantage.

Lighting

Night driving in kangaroo country demands serious light, so a 40-inch front-facing LED light bar throws distance illumination well beyond the factory candles, while side-facing LED scene lights turn the campsite and the kitchen side of the truck into a workable space after dark.

Interior Modifications – Structural Storage & Power

The interior of the Y60 has been completely reimagined and repurposed for cargo storage. The rear seats were ditched in favor of the removable false-floor storage system with a 100-liter internal freshwater tank fed by a high-pressure Flojet pump. It sits as low and as far forward as physically possible, keeping the center of mass between the axles. The remaining space is partitioned for dry food, shower gear, and camera equipment, plus a dedicated padded dog platform with its own 12V fan for outback heat.

The smartest packaging trick is at the rear windows, where the factory sliding glass was replaced with Emu Wing gullwing hatches. The driver’s side opens to instant, standing-height access to an ARB twin air compressor with a 6-liter reservoir tank – airing up four 35s without unpacking a thing – plus a fold-down vanity mirror.

The passenger side is the 12V system center with two 150Ah AGM batteries (300Ah total), a Ctek D250S DC-DC charger with SmartPass, a Ctek lithium charger, and a 2500W inverter, all reachable in seconds in case of any problem.

Up front, the cabin got the same attention as the cargo area. It has the electrically heated and cooled Recaro seats with matching Recaro-material door trims, full-floor sound deadening and acoustic matting under fresh carpet, a Nardi black leather steering wheel, a custom stainless dash pod for switches and gauges, and 35% tint.

The comfort list runs deep – a 16-inch 12V TV on a swing-out arm, a JBL camp speaker, a mini retro Super Nintendo, a suspended paracord laptop tray, and a custom switch panel tying the electrical system together. It’s a rolling apartment, but every gram of it is mounted low and secured.

List of Mods

Wheels & Tires

• 16×8, -22 offset steel wheels
• 315/75R16 (35-inch) Nitto Trail Grappler mud-terrain tyres

Suspension & Drivetrain

• 5-inch lift using King heavy-duty coil springs (front and rear)
• King Shocks 2.5-inch smooth-body adjustable shocks with remote reservoirs
• Superior Engineering chromoly adjustable panhard rods and radius links
• Widened GU (Y61) axles front and rear
• Front automatic locker
• Rear limited-slip differential (LSD), tightly shimmed
• 4.6 differential gears
• Fully braced axle housings with weld-on bash guards
• DBA kangaroo-paw slotted brake rotors
• Rebuilt TB48 twin-piston brake calipers
• Airbag Man helper airbags fitted inside the rear coils (load levelling)

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Engine and Performance

• Rebuilt factory silver-top TD42 4.2L diesel engine (GU turbo internals)
• Garrett GT3076 turbocharger running ~36 psi boost
• 4-inch stainless steel snorkel
• Patrol Doctor high-flow airbox
• Front-mount PWR intercooler with custom-shaved grille and custom piping
• 3.5-inch stainless steel exhaust (straight-pipe)
• 12mm high-flow fuel pump
• Larger injectors
• Larger alloy radiator
• 90-litre primary fuel tank + 78-litre Brown Davis auxiliary sub-tank (168L total)

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Exterior & Armor

• Custom high-clearance front bull bar with integrated hoops/brush bars
• 9,500 lb recovery winch with removable stainless cover plate
• Quick-connect utility ports: air hose, hot-water (engine-bay heat exchanger), Anderson plug
• Dual GME antennas on folding mounts (one used as a height-clearance gauge)
• Chassis-mounted rock sliders
• Side brush bars (tyre-width legal coverage)
• Custom quarter-panel guard hoops into rear bar
• Dual-pivot swing-away rear bar (spare tyre + gear/laundry bag with Scrubba bag)
• Custom 2.5mm aluminum kitchen box: slide-out cooking area (stove, Jetboil, dry food, USB charging, dimmable LED strips), 34L gravity-fed water tank, gas bottle storage
• Custom-built roof rack

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Lighting

• 40-inch front-facing LED light bar
• Side-facing LED scene lights

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Overland Gear

• Bundutec Bundutop electric clamshell rooftop tent with 130W flexible solar panel
• 270° Foxwing awning with Super Peg spigot poles (no guy-lines)
• ExPed Megamat Duo self-inflating mattress (rooftop tent)

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Interior Modifications

• Electrically heated/cooled Recaro front seats, matching Recaro-material door trims
• Full-floor sound deadening, acoustic matting, fresh carpet
• Nardi black leather steering wheel
• Custom stainless steel dash pod for switches/gauges
• Outback roof console with dual GME UHF radios
• 35% window tint
• Rear seats deleted, replaced with custom structural alloy frame
• False-floor storage system (removable)
• Built-in water tank under false floor + Flojet pump feeding 100L internal freshwater tank
• Dry food, shower, and camera gear storage; padded dog platform with 12V fan
• Driver’s-side Emu Wing hatch: ARB twin air compressor, 6L reservoir tank, fold-down vanity mirror
• Passenger’s-side Emu Wing hatch: main 12V electrical hub with two 150Ah AGM batteries (300Ah), Ctek D250S DC-DC charger, SmartPass system, Ctek lithium charger, 2500W inverter
• 16-inch 12V TV on swing-out arm
• JBL camp speaker
• Mini retro Super Nintendo system
• Suspended paracord laptop tray
• Custom switch panel/electrical controls

Conclusion

Of course, calling this “the ultimate Nissan Patrol Y60 overland build” is a big claim, but the build sheet totally backs it up. Every weakness of the platform has been sorted out, starting from the underpowered TD42 to the widened GU axles and front locking differentials, making it a reliable and exceptionally capable 4×4 platform.

The overland section of the build is executed on the absolute top level with ideal weight distribution, safe placement of the electrical components, and convenient-to-use gear that covers every single need of the owner when out in the bush.

All in, the modifications on this Patrol land at an estimated $40,000-75,000+ in parts depending on component choices and how much fabrication is done at home, with professional labor (engine build, axle swap and gear setup, suspension install) adding another $8,000-15,000 if farmed out. This totals up to around $100,000 for everything installed and ready to drive.

On our 70-point scale, this Patrol earns a perfect 70 out of 70 – the maximum Build Off-road Rating we can award. It starts from a 4WD with a suspension lift on heavily oversized 35-inch tires (30 points), then stacks every available extra: the front automatic locker (+10), the rear limited-slip differential (+10), dual-range low gearing (+10), body-on-frame construction (+5), and comprehensive body armor with chassis-mounted protection (+5). It’s the rare build that leaves nothing on the table.

Watch the progress and find out more about this Nissan Patrol Y60 overland build by visiting the Instagram profile of the owner: @overlandobsessed!

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