Dakar 2026 from the Inside: A Rally Engineer from Ukraine on Breakdowns, Suspension, and 4x4 Preparation

The «Dakar 2026» rally marathon in Saudi Arabia became the ultimate challenge for vehicles and equipment. This event proved especially valuable for Ukraine: our fellow countryman Mykhailo Onufriichuk — a rally engineer and hands-on specialist with many years of experience in European rally teams (Toyota, Ford). He worked his way up from truck mechanic to rally engineer and prepared a production Ford Bronco Raptor for a Canadian racing team. His unique 24/7 working experience offers a completely different perspective on preparing civilian SUVs for extreme conditions.

What Dakar revealed about the production Ford Bronco Raptor

The team competed in the Ultimate Score category using an almost stock vehicle, which highlighted the main weak points of civilian platforms in desert conditions:

• Problem #1 — Cooling: Due to extreme heat (+35...40°C) and heavy sand conditions, the factory cooling system and fuel system overheated and required serious engineering upgrades.
• Electronics: Modern Bronco onboard computers turned out to be sensitive to extremely high temperatures.
• Engine: Unlike other components, the factory Bronco Raptor engine survived all critical overheating situations and proved its reliability.

The most critical components in extreme conditions

Daily life at Dakar means stages of up to 1000 km every day. Mykhailo highlighted four critical points of the vehicle:

• Suspension: The main source of costs and failures. Stock Fox 3.1 shock absorbers could not withstand the rally pace. The team carried a massive запас: 24 shock absorbers and 6 sets of front control arms, which broke far more often than the rear ones due to constant impacts.
• Protection: Reliable skid plates are the only thing protecting the engine oil pan, transmission, and transfer case on rocky sections.
• Snorkel: A mandatory component that protects the engine from fine sand and dust in desert conditions.
• Winch: A vital self-recovery tool when a heavy vehicle gets high-centered in soft dunes.

Dakar experience for Ukrainian off-roading

Unlike the high-speed gravel and sands of Saudi Arabia, Ukrainian conditions (Carpathian Mountains, mud terrain) require different priorities.

For liquid mud, three locking differentials are necessary. 

Since vehicles in Ukraine often cross deep water fords, it is important not only to install a snorkel but also to reroute axle breathers and create positive pressure in the axles to prevent water from entering through the seals.

The biggest mistake enthusiasts make is focusing on exterior tuning instead of safety. An internal roll cage repeatedly saved the lives of Mykhailo’s clients in the Carpathians: after a rollover, the vehicle was simply put back on its wheels, oil was topped up, and it continued driving.

Where to start with 4x4 preparation

For those planning to prepare their civilian vehicle for expeditions or mountain tourism, the rally engineer recommends following a simple and logical algorithm:

• Proper tire selection: Switching to larger, serious mud-terrain tires is the foundation for improving off-road capability. However, the engineer warns that with a significant increase in tire size, it is essential to optimize axle gear ratios (change the differential gears) to reduce stress on the factory engine and preserve its lifespan.
• Suspension from market leaders: For classic overlanding and tourism, there is no need to invent complicated custom suspension setups. It is best to choose ready-made reinforced suspension kits from leading global brands. They already feature professionally engineered factory settings designed for a specific vehicle weight and geometry. Expensive racing shock absorbers are only necessary when performing serious engine tuning for high-speed driving.
• Armor protection and recovery equipment: Any preparation for rough terrain should begin with reliable underbody protection — installing durable skid plates for the engine and transmission, as well as rock sliders. In addition, integrating a quality winch is a mandatory element that allows the driver to recover the vehicle independently from almost any trap.

Advice from Mykhailo: Build your vehicle for a specific purpose. If the vehicle spends 90% of its time on asphalt, aggressive off-road tuning makes little sense.

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