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Syncro has sat for 20+ years let’s resurrect it!
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UtahGOgear
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PostPosted: Wed Mar 26, 2025 12:32 pm    Post subject: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Shocked well I jumped head first into this Syncro. It popped up on our local classifieds and the seller had posted one about a month ago that was silver and sold immediately so when I saw this one I jumped on it for $3,000. The guys had repossessed a bunch of Vanagons from a shop I guess and got titles for them as a tow company. I registered this and I’m real excited to get it going again. I have several questions and welcome any and all opinions. Hopefully together we can get this back on the road. I’ve owned one other Syncro which was this same color but very very rusty and sold it in short order as it was too much metal work for me to confidentially tackle. This one is luckily really dry as far as the body goes. With around 118,000 miles on the clock it’s a gem in my book.

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I know it’s sat for about 20 years or more. I took the vice grips off the fuel line thinking the tank was dry and sadly the next day realized it wasn’t. A forbidden molasses type gooey mix was what we found underneath. I poured about 3 gallons of gas into the tank after breaking the gas cap which was stuck solid. The fill cap area looks rusty- I hope little or no water got into the tank. I have a borescope to look into it tonight after I get home from work and we’ll see I bought a cap from orylies but it actually wasn’t for a Syncro but a 2nd and didn’t fit sadly.

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A big concern is the ac venting that looks like it straight up just got too brittle and fell right off. What do you think, is there any saving this mess? Better to try and find some from another van to install? Maybe can I just use the ac if it works and blast it out the back and just not have these ducts?
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I’m pretty excited to take this on. Here’s the options sticker that’s still under the dash.
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So far I’ve tried flushing the tank and after like 3 gallons it did start coming out clear. We’ll take a peak inside tonight.


I’m worried because there’s hardly any coolant in the system, none in the overflow or tank. Maybe it seeped out of somewhere? I’ve got more to put in this week. I found a receipt for head gaskets being done previously. Hope they didn’t blow again.
I got new fuel line to replace all fuel line.
I got a new Bosch fuel pump. The fuel pump was missing when I bought it, so I hope it was parked for that reason and not a lack of coolant.
I got new spark plugs, will check cylinders to see if any water got in.
Plan to change the oil and add marvel mystery oil after some sea foam flush in the old oil for a little bit. Is that okay or will it eat at seals?
I got a new little boot that was torn that goes before the air box after the piping that comes from behind the passenger tail light. What’s the little box for in there?? Does it collect water or something and need to be emptied?
Got some 27x8.5r14 tires from Amazon to roll with for now.
Got some truck mirrors I’m real excited about mostly for fun.
Got a locking gas cap that’s actually for a Syncro.

What do you guys think, is there anything that’s missing to just get it up and running? I had it going on starter fluid for a bit after several cycles to get oil around and it sounded great. What else would you do before getting it back on the road? I plan to get it going then do more maintenance as I use it. What’s your go to list or things off the top of your head?
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dobryan
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PostPosted: Wed Mar 26, 2025 1:57 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Welcome to the madness! Cool
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PostPosted: Wed Mar 26, 2025 2:06 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Buy a coolant pressure tester, so you can pressurize the coolant system and see if it holds pressure. This way you don't go to the trouble of filling it, only to find a leak, or multiple leaks from previous never completed repairs, or just age attacking something else in the Coolant system from sitting... Think Think
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PostPosted: Wed Mar 26, 2025 2:47 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Nice Find! If it were me, I would be changing every hose and seal that I could. Sitting that long, everything will be dried out and cracked. All fluids and grease, too.
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PostPosted: Wed Mar 26, 2025 3:22 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

My van was also found in a field in Utah after being abandoned, and I paid the same amount for it about 9 years ago- good find!

Looks like a lot of fun, no doubt you've got your work cut out for ya!
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PostPosted: Wed Mar 26, 2025 9:01 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

$3000 Syncro…nice! Very Happy

Prob’ly only end up costing you maybe $20-25k… Wink

Sorry, kidding…Looking forward to your progress! Cool

- Dave
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Herr Motorspiele
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PostPosted: Thu Mar 27, 2025 7:12 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Inspect and grease all 8 cv boots.
I’d replace all rubber brake hoses and do a flush, that’s cheap peace of mind they can swell up over time.
Check steering rack boots too.
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Phishman068
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PostPosted: Thu Mar 27, 2025 9:32 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

I routinely buy busses that have been parked for 20+ years and bring them back to life. A few things to keep in mind:
DO NOT TURN THAT ENGINE OVER WITHOUT PUTTING OIL IN THE CYLINDERS, the rings will absolutely break and you're at square zero. Pull all the plugs, put a 10 second or so shot of WD40 into each plug hole, then turn it over by hand a few times, then add more WD40 and do it some more. I like to really fog the crap out of those cylinders before bringing them back to life and before ever engaging the starter. Ya, it'll be smokey once it fires up, but it'll get ya there.

Flush the gas tank.
There's usually thick tar like sludge in syncro tanks. Pull the fuel pump and push a lot of fuel through there. Then put a new filter, pump, etc on.

Be cautious with the electrical systems and the process of bringing them back onboard.

Make sure there's oil in it.

Get the injectors clicking with an 18v battery before you try using them, or you'll just wash out certain cylinders while others aren't coming to life yet. A little tap tap tap with 18Volts will bring them from making no noise to properly and consistently activating the solenoids in there. Once you're hearing good clicks, then and only then should you plug them in and hope for life.

Testing the cooling system with a pressure tester before getting the engine running is always a wise plan as well.

Change the gear oil before driving it- the transmission is worth more than the rest of the car!

Welcome to the madness!
It's fun!
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PostPosted: Thu Mar 27, 2025 6:28 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Congrats! I just bought a syncro a few months ago that had been sitting for 20 years and was in a similar boat. I had no coolant, a crud full gas tank and a bad fuel pump. I would start with replacing all the coolant lines. I found one of the coolant distribution pipes had a hole in it and another pipe was close to failure. All the work is in my thread in my sig line.

Good luck!

Aiden
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PostPosted: Thu Mar 27, 2025 6:46 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Ceckert64 wrote:
Congrats! I just bought a syncro a few months ago that had been sitting for 20 years and was in a similar boat. I had no coolant, a crud full gas tank and a bad fuel pump. I would start with replacing all the coolant lines. I found one of the coolant distribution pipes had a hole in it and another pipe was close to failure. All the work is in my thread in my sig line.

Good luck!

Aiden


That's great news Aiden! Other than a Thing, a Syncro is the only other VW that's on my radar. I look forward to diving into your Syncro thread.
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UtahGOgear
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PostPosted: Fri Mar 28, 2025 6:58 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

dobryan wrote:
Welcome to the madness! Cool


Thanks! Haha a bit different than what I'm used to, that's for sure.

jlrftype7 wrote:
Buy a coolant pressure tester, so you can pressurize the coolant system and see if it holds pressure. This way you don't go to the trouble of filling it, only to find a leak, or multiple leaks from previous never completed repairs, or just age attacking something else in the Coolant system from sitting... Think Think


That's a great idea, I plan to replace all the rubber tubes and hoses. I think it was abandon because the fuel pump as that was missing but maybe they took it out for another van or something.

Christopholi wrote:
Nice Find! If it were me, I would be changing every hose and seal that I could. Sitting that long, everything will be dried out and cracked. All fluids and grease, too.


I will replace everything that I can! Today I will be tackling the fuel lines. Next will be coolant hoses followed by vacuum lines and any other rubber parts.

Mikesarge wrote:
My van was also found in a field in Utah after being abandoned, and I paid the same amount for it about 9 years ago- good find!

Looks like a lot of fun, no doubt you've got your work cut out for ya!


Awesome! I've had good luck finding fun projects here in Utah, getting harder to come by it seems as the population grows but there always seems to be a deal out there.

dhaavers wrote:
$3000 Syncro…nice! Very Happy

Prob’ly only end up costing you maybe $20-25k… Wink

Sorry, kidding…Looking forward to your progress! Cool

- Dave


Haha seriously though! I've already doubled the $3,000 I have into it on fluids, mirrors (okay I didn't need the truck mirrors but I got excited), fuel lines, fuel pump, fuel filter, spark plugs, 27x8.5r14 tires, bettery, and a lot of degreaser and other odds and ends. I do have high hopes of not being over $6,500 into it total and having it up and running in the next few weeks. So realistically I'll be into it closer to twice that amount and it'll be done in a few months Laughing

Herr Motorspiele wrote:
Inspect and grease all 8 cv boots.
I’d replace all rubber brake hoses and do a flush, that’s cheap peace of mind they can swell up over time.
Check steering rack boots too.


I'll plan on that! Is the red heavy duty grease I use for most things okay? I noticed one boot was torn which is a bummer. I'll have to get that soon.

Phishman068 wrote:
I routinely buy busses that have been parked for 20+ years and bring them back to life. A few things to keep in mind:
DO NOT TURN THAT ENGINE OVER WITHOUT PUTTING OIL IN THE CYLINDERS, the rings will absolutely break and you're at square zero. Pull all the plugs, put a 10 second or so shot of WD40 into each plug hole, then turn it over by hand a few times, then add more WD40 and do it some more. I like to really fog the crap out of those cylinders before bringing them back to life and before ever engaging the starter. Ya, it'll be smokey once it fires up, but it'll get ya there.

Flush the gas tank.
There's usually thick tar like sludge in syncro tanks. Pull the fuel pump and push a lot of fuel through there. Then put a new filter, pump, etc on.

Be cautious with the electrical systems and the process of bringing them back onboard.

Make sure there's oil in it.

Get the injectors clicking with an 18v battery before you try using them, or you'll just wash out certain cylinders while others aren't coming to life yet. A little tap tap tap with 18Volts will bring them from making no noise to properly and consistently activating the solenoids in there. Once you're hearing good clicks, then and only then should you plug them in and hope for life.

Testing the cooling system with a pressure tester before getting the engine running is always a wise plan as well.

Change the gear oil before driving it- the transmission is worth more than the rest of the car!

Welcome to the madness!
It's fun!


Shocked Well I hope my rings aren't broken! I cycled it for a while to get oil moving around before doing a compression test, but I did not put any oil in the cylinders. I got it going with starter fluid just to listen to it for a bit and it sounded nice. The fuel looked really clean when I took an injector out so I guess just the tank got contaminated or something. I did not think much about the gear oil but now that you mention it that does seem vital! I'll get that done asap.

Ceckert64 wrote:
Congrats! I just bought a syncro a few months ago that had been sitting for 20 years and was in a similar boat. I had no coolant, a crud full gas tank and a bad fuel pump. I would start with replacing all the coolant lines. I found one of the coolant distribution pipes had a hole in it and another pipe was close to failure. All the work is in my thread in my sig line.

Good luck!

Aiden


Hey, I've seen your thread! I like the action photos of the van! Hopefully I can get mine running as fast as you did and get it out there on the open road as well. Yours sure cleaned up nice! Very motivating thread, thanks for posting and for the good luck haha
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UtahGOgear
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PostPosted: Fri Mar 28, 2025 7:05 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Thanks for all your replies with great advice and motivating words, I appreciate it!

Jack and I got to work yesterday while the weather was nice and replaced the spark plugs. We figured we’d take compression while they old spark plugs were out. All cylinders read around 100psi so it seems healthy.


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Check out the first fuel clamp off an injector, it was easy to just break off which concerned me. I guess it’s a good thing they’re getting replaced with stainless steel clamps and obviously new fuel line all around.
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PostPosted: Fri Mar 28, 2025 10:16 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Did you drop oil in the cylinders when you swapped spark plugs? I would still do that if you didn't. I like to use a bit of ATF.
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UtahGOgear
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PostPosted: Fri Mar 28, 2025 6:43 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

4Gears4Tires wrote:
Did you drop oil in the cylinders when you swapped spark plugs? I would still do that if you didn't. I like to use a bit of ATF.


I put a bit of marvel mystery oil in them, hopefully it helps. Got a borescope in there and they looked good from what I could tell- no scoring or the like.
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UtahGOgear
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PostPosted: Fri Mar 28, 2025 6:57 pm    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

NOT GOOD! I thought Amazon sent the wrong fuel line, but it turns out I was a confused duface and ordered some good old low pressure fuel line for a carburetor setup. Glad I read the hose before installing any of it! I pulled a line to start and the lettering was well preserved under a heat sleeve. Looks like it was made the 42nd week of ‘86? That’s what I figure but who knows. Do you? I do believe/know it’s the original fuel line which is terrifying haha. I’m excited to get some high quality 300psi working load fuel line rated for all fuels and such. I had totally just ordered the wrong one. Silly me. Check out the wrong hose- I cut a piece dang it! And the original hose.


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Bad hose line to use on a fuel injected system when it straight up says don’t use for fuel injected system. 50psi would have blown fast. I wonder how many have gone up in smoke (no pun intended Cheech and Chong) because of this simple mistake or not reading the actual rating of the hose?


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42/86 date stamp or do you know something I don’t?

Also I’m very sad to spend nearly $500 on truck mirrors for them to not come with the dang gaskets and bolts. I re-use the same hardware then have to buy some to fit the upper bracket? Am I crazy here wondering why they can’t include a few more bolts when I pay stupid money for some mirrors? I’ll be hitting Ace tomorrow for some stainless steel bolts unless I’ve got some on hand in the rivnut kit which I might use to secure the top bracket- unless anyone has any other advice on doing that or I jump the gun and use self tappers promising myself I rivnut later on in life but never actually do. The driver side mirror is gone with its bolts so that’s a bummer or else I’d just reuse em.
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'78 Transporter Moon Roof Camper Conversion
'78 Westy Restoration
'85 Westy 1.8T AEB 50* w/adapter plate
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PostPosted: Sat Mar 29, 2025 5:57 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

UtahGOgear wrote:
Also I’m very sad to spend nearly $500 on truck mirrors for them to not come with the dang gaskets and bolts. I re-use the same hardware then have to buy some to fit the upper bracket? Am I crazy here wondering why they can’t include a few more bolts when I pay stupid money for some mirrors? I’ll be hitting Ace tomorrow for some stainless steel bolts unless I’ve got some on hand in the rivnut kit which I might use to secure the top bracket- unless anyone has any other advice on doing that or I jump the gun and use self tappers promising myself I rivnut later on in life but never actually do. The driver side mirror is gone with its bolts so that’s a bummer or else I’d just reuse em.


I hope your kit came with the mirror spacer, and if so, don’t forget to have it installed before marking/drilling the holes for the rivnuts. It will slightly push the mirror to the side and position it in the right location to drill the holes.

I didn’t do that for my first mirror, and my hole ended up slightly overlapping a structural part of the door, not allowing the installation of the rivnut (had to very patiently file away insider metal to fit the rivnut). I think I have a post somewhere where I asked about it and how terrified I was of having screwed my door completely.

UPDATE: found the thread describing the mistake I made while installing the mirrors
https://www.thesamba.com/vw/forum/viewtopic.php?t=720821
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PostPosted: Sat Mar 29, 2025 8:27 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

UtahGOgear wrote:

A big concern is the ac venting that looks like it straight up just got too brittle and fell right off. What do you think, is there any saving this mess? Better to try and find some from another van to install? Maybe can I just use the ac if it works and blast it out the back and just not have these ducts?


Looks like you have your hands full but when you get past the mechanicals and get to the interior... the AC tunnel that runs along the roof... that issue was deemed to be so common and dangerous that VW issued a recall for it. I don't have the TSB for it anymore but I took my van to the dealer and had them install the fix for it. However, mine had not crashed down yet like yours has. Still might be worth a phone call if you want to know your options. They were not thrilled with me, but a recall is a recall Very Happy
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PostPosted: Sun Mar 30, 2025 9:08 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Got new tires installed yesterday! They’re only an inch or two bigger than stock by comparison. They are 27/8.5r14 on the original alloys. I have had this same size tire on our 1.8t westy and it was awesome. I think it’s the biggest I’d feel comfortable running on the stock 2.1 motor. The other ones on the westy are general grabbers which are nice. I’ve heard these ones are quieter from reviews on Amazon where I bought them from. They ran me $500. I put new valves in and when taking the old valve stems out from the old ones I noticed they were all different which was weird I thought. Anyway, I love how these look! Here’s the title on the Amazon listing so you can get ya some if interested or if you find a problem with using them I’m extremely open to knowing what you think you won’t hurt my feelings telling me I’ve made a mistake I appreciate all opinions and insights :
Forceum M/T 08 Plus Mud Off-Road Light Truck Radial Tire-27X8.50R14LT 27X8.50X14 27X8.50-14 95Q Load Range C LRC 6-Ply BSW Black Side Wall


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pnwkayaker wrote:


I hope your kit came with the mirror Surprised spacer, and if so, don’t forget to have it installed before marking/drilling the holes for the rivnuts. It will slightly push the mirror to the side and position it in the right location to drill the holes.

I didn’t do that for my first mirror, and my hole ended up slightly overlapping a structural part of the door, not allowing the installation of the rivnut (had to very patiently file away insider metal to fit the rivnut). I think I have a post somewhere where I asked about it and how terrified I was of having screwed my door completely.

UPDATE: found the thread describing the mistake I made while installing the mirrors
https://www.thesamba.com/vw/forum/viewtopic.php?t=720821


Okay I did read that and still struggled with the rivnuts haha. Mostly because my tool was too large to get that side on in correctly. It still worked but was insanely hard to screw into maybe I cross threaded it not sure. It’s on there though! The rivnut made it stick out a bit and I wish I had used self tappers but all the screws now match so whatever.

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S4VAGE wrote:


Looks like you have your hands full but when you get past the mechanicals and get to the interior... the AC tunnel that runs along the roof... that issue was deemed to be so common and dangerous that VW issued a recall for it. I don't have the TSB for it anymore but I took my van to the dealer and had them install the fix for it. However, mine had not crashed down yet like yours has. Still might be worth a phone call if you want to know your options. They were not thrilled with me, but a recall is a recall Very Happy


No kidding! I will for sure be calling just to see if it’s a recall they will or can honor. That would be ridiculous but you’re right a recall is a recall! Haha we’ll see!


Fuel lines came in and are installed as well as the new Bosch fuel pump. She starts up! Next up is the coolant flush and refill/bleed. I will be replacing every hose but not immediately. I’d like to be able to drive it to work to wrench on it there. I put 2/3 can of sea foam in the tank and 1/3 can in the case. I plan to run it for a few minutes and then change the oil with 20/50 and marvel mystery. I’m excited to try and drive it!

I noticed headlights and front signals don’t work. Brights come on though. Maybe dead bulbs if I’m lucky? Weird that the high beams work but not low beams. Maybe I check relays/fuses and find something. We’ll see. I’m very excited! Our kids are having lots of fun too working on it, I can’t wait to bring them out to Moab!
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RIP:
'82 Westy a/c
'82 Westy 1.6D
'78 Transporter Moon Roof Camper Conversion
'78 Westy Restoration
'85 Westy 1.8T AEB 50* w/adapter plate
'87 Syncro 2.1 WBX
'91 1.8T ATW 50* w/diesel components
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zerotofifty
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PostPosted: Sun Mar 30, 2025 9:39 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

Tires from a quad runner? Havent seen such sized MT tires before. Interesting!!!
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dhaavers
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PostPosted: Sun Mar 30, 2025 9:46 am    Post subject: Re: Syncro has sat for 20+ years let’s resurrect it! Reply with quote

I looked at those tires for my 1wd but stayed with the Grabbers, I’ve been happy with them.

Utah tires, fer sure! Wink

- Dave
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