Work on the chassis

In autumn 17 the work on the chassis started. Part of the chassis work was done at the end of the completion process.


Engine / gearbox / tires

  • New front protection plate for the engine, because the Mercedes Vario unfortunately has a plastic oil pan
  • Replacement of the standard valve by a Rölex valve to protect the oil pan
  • Removal of the speed limit of 80kmh (vehicle will be registered as an RV and not as a truck anymore)
  • As it is too expensive to replace the shorter gear transmission through a longer gear transmission (to reduce rpm) we decided to install larger Michelin tires XZY 9.5 R17.5, which are still approved by Mercedes Benz

Driver cabin

  • Removal of the flooring and replacement with noise-reducing materials
  • Burglary protection for driver and passenger doors

Chassis optimisation

  • Sandblasting of the chassis, anti-corrosion treatment and new painting in black
  • Sandblasting of the tire rims, anti-corrosion treatment and new painting in black
  • Heavy duty shock absorbers by MARQUART, to reduce swing movements of the vehicle while driving
  • Triple leaf springs on the front axle instead of double leaf springs
  • Removal of the heavy trailer hitch and of all power connections to the trailer to save weight
  • Removal of the spare tire holder under the chassis, as spare tire will be placed on the back side of the body
  • Exhaust: moved forward to make room for an additional diesel tank and pipe lifted to improve ground clearance

Pictures before chassis painting

Pictures after painting

Larger tires

We replaced the tires sized 215/75 R17.5 by new Michelin XZY 9.5 R17.5. These new tires are designed for onroad and offroad. In addition, the tires have an approval for use during winter. On the other side:  New rims 6.75 x 5.17 are required. Rims are painted in black.


Important: This tire format has the official approval by Mercedes Benz.


The following pictures illustrate the size difference to the old tires. As a result, with the new tires we achieve nearly 4 cm more ground clearance and a 10% reduction in rpm.