Joey P.
1/5
In late 2024, I entrusted my 2011 Ford E250 van, equipped with a DIY 4x4 conversion, to Sportsman Light Truck in Kamloops, BC. My primary concern was severe steering wander, but I also requested other work. With no time constraints, I drove from Edmonton, AB, to Kamloops, dropped off the van for the winter, and flew home, expecting quality work given their $150/hr rate and reputation.
Steering Wander Issues
The van’s steering wander, which made it difficult to maintain lane control, was my primary concern. Sportsman performed work on the steering geometry and replaced ball joints, but only on one side, despite disassembling both sides for front differential regearing. This decision was perplexing, as replacing ball joints in pairs is standard practice to ensure balanced performance and longevity. The process of removing locking hubs, brakes, rotors, wheel hubs, and axle shafts for regearing left little additional labor to replace the other side’s ball joints, yet this was not done. Additionally, the outer tie rod ends, which were visibly worn and audibly clicking—a clear sign of failure—were not addressed. For a professional shop charging premium rates, failing to address such basic components raises serious questions about their thoroughness.
Driveline Vibration
A significant new issue emerged after the shop’s work: a pronounced driveline vibration above 90 km/h, which was not present before. Sportsman claimed they rebalanced the driveshaft twice and installed an $800 double cardan joint to mitigate it, but the vibration persisted. They attributed it to higher gear ratios from the differential regearing, stating that faster driveshaft rotation amplifies vibrations. However, consultations with driveline specialists confirmed that a properly balanced driveshaft should not vibrate, even with higher gear ratios.
Custom Gas Tank Installation
The custom extended-range gas tank installation was a major disappointment. Relocating the EVAP unit during the install caused a check engine light. More alarmingly, the auxiliary fuel line for my air gas heater was poorly executed. Despite my explicit request for a properly integrated line, the shop installed an oversized line with improper fittings, inadequately secured. During a road trip, this line flopped around, contacted the exhaust, and melted, causing a dangerous fuel leak when refilling at a gas station. I had to crawl under the van to make a temporary repair. This safety hazard reflects gross negligence. I now face the significant task of dropping the tank to replace the auxiliary line properly.
Brake Performance
I specifically requested improvements to the van’s braking performance, as the brakes felt soft and spongy. Sportsman replaced the rear rotors and pads but made no noticeable improvement. After pickup, I performed a brake fluid flush and bleed myself, which took less than an hour and drastically enhanced braking performance. Further inspection revealed seized front brake pistons causing rubbing, which the shop failed to diagnose. The oversight of these fundamental brake system issues—fluid condition and seized pistons—further underscores the shop’s incomplete diagnostics.
After the shop installed dash switches, the ABS light began illuminating randomly. While this could be coincidental, the timing suggests possible wiring or grounding issues introduced during the installation. Throughout the process, Sportsman provided updates, but their customer service fell short upon pickup. I scheduled a follow-up visit on July 16, 2025, via email with owner Brady Erixon to address the issues. Upon arrival, Brady seemed unaware of the appointment and was dismissive, attributing all problems to the van’s DIY 4x4 conversion. While the conversion presented challenges, issues like the gas tank, brakes, and electrical problems are unrelated. During a test drive with technician Steve, he acknowledged the steering was inferior to their other 4x4 vans, validating my concerns, but no actionable resolution was offered. The work order listed Bryan Goetz as the technician.
