Complete G550 4×4² Portal Axle Conversion for Mercedes G-class W463

The Ultimate Solution: Portal Axles & 4″ Suspension Lift

G-wagon enthusiasts now have the opportunity to achieve a remarkable 10-12″ net lift by combining a portal axle conversion, a 2″ or 4″ lift kit, and 37″ tires. This comprehensive setup allows your Mercedes G-class W463 to attain the same impressive heights—and widths—as the celebrated G550 4×4². However, it’s crucial to understand that the portal axle conversion and the lift kit are not all-inclusive solutions on their own. Depending on your goals, you can opt for one or combine both to elevate your vehicle’s performance and appearance to unprecedented levels.

Why Choose a Portal Axle Conversion?

A portal axle conversion is an ideal choice for those who want to:

• Lift their vehicle by 5 inches.
• Gain substantial ground clearance.
• Accommodate larger tires.
• Achieve a wider stance.
• Add larger fender flares.
• Avoid modifying the suspension or its geometry.

With a portal axle conversion, you can install 35″ tires and complete the transformation. This setup ensures no error codes, no issues, and retains the stock suspension, providing a straightforward and effective solution for enhancing your G-wagon.

The Alternative: 4″ Lift Kit

Alternatively, you can choose to install a 4″ lift kit and add 35″ tires. However, this option does not provide the same ground clearance or width/stance as the portal axle conversion. There may also be issues related to changing the suspension geometry and tire size, potentially affecting the ABS and ESP systems. While we offer products to address these changes, the solutions for tire size-related issues are not always foolproof. Nonetheless, our Project Car with a 4″ lift kit and 35″ tires has had no problems, proving that this can be a viable option for some users.

Portal Kit Overview

What is a Portal Kit?

A portal kit essentially consists of portal boxes that bolt to your existing hubs. The wheels then attach to the bottom of the portal, lifting the entire vehicle (from the axle up) off the ground. This innovative design provides significant advantages in terms of ground clearance and overall vehicle height.

Key Features of the Portal Kit

• Bolt-On Installation: Portals bolt onto your existing axles, providing an instant 125 mm lift (~5 inches).
• Additional Lift: Combine with our 4″ lift kit and larger tires for an even greater height increase.
• Proprietary 4-Gear Design:
  • Maintains the turning momentum of the wheels.
  • Reduces load and stress on gear teeth.
  • Lowers the temperature in the portal box.
• Optimized Gear Ratio: The 1.22:1 gear ratio matches larger tire sizes to maintain power and acceleration. This reduces drivetrain stress and strain, ensuring a smooth and powerful performance.
• Advanced Wheel Sensors: Newly developed sensors ensure your ABS and ESP systems function properly without errors or codes.
• Minimal Additional Changes: No costly modifications to the suspension, steering, or differential are required, making this a cost-effective upgrade.
• Tire Compatibility: Suitable for tire sizes between 255/85R16 (33″) and 315/75-16 (35″). For larger tires, such as 37″, further inquiries are necessary to ensure compatibility and optimal performance.
• Weight Limitations: The vehicle’s gross weight should not exceed 3.5 tons (3500 kg) to maintain the warranty and ensure safe operation.
• Warranty and Installation: Includes a manufacturer’s limited 1-year warranty against defects in materials and craftsmanship. Installation should be performed by a skilled and trained mechanic to ensure the best results.

Kit Components

The portal axle kit includes:

• 4 Portal Boxes with Pre-installed Gears
• 2 Front Outer Steering Knuckles
• 2 Heavy Duty Front CV Joints
• 2 Heavy Duty Rear Axle Shafts
• 2 Rear Brake Calipers with Integrated Parking Brake
• Set of Axle Braces for Front & Rear Axles
• 4 ABS Sensors
• Mounting Bolts

Achieving the G550 4×4² Look

This package provides the off-road capability, width, and height similar to the G550 4×4². It assumes the use of your stock wheels but allows for additional components like Beadlock Wheels or Electric Side Steps. For a more complete transformation, including dual shocks, rear tube bumper, side markers and mirrors, 22″ forged wheels, and the 4×4 emblem, we can provide the necessary parts to ensure your G-wagon stands out both in performance and aesthetics.

Installation Process

The installation of the portal axle kit is a straightforward process but requires precision and expertise. It’s recommended to have the installation done by a skilled mechanic to ensure all components are properly fitted and functioning. The process involves bolting the portal boxes onto the existing hubs, installing the new steering knuckles, CV joints, and axle shafts, and ensuring all sensors and brake calipers are correctly positioned and calibrated.

Performance and Practicality

Once installed, the portal axle conversion significantly enhances the vehicle’s off-road capabilities. The increased ground clearance allows for tackling rough terrains with ease, while the optimized gear ratio ensures the vehicle retains its power and acceleration even with larger tires. The advanced wheel sensors maintain the functionality of ABS and ESP systems, ensuring safety and reliability during your adventures.

Real-World Applications

The portal axle conversion is not just for show; it provides real-world benefits for off-road enthusiasts. Whether you’re navigating rocky trails, deep mud, or uneven terrain, the increased ground clearance and robust construction of the portal axles ensure your G-wagon can handle it all. The wider stance also improves stability, reducing the risk of tipping over on steep inclines or uneven surfaces.

Customization Options

For those looking to customize their G-wagon further, we offer additional components and accessories to complement the portal axle conversion. From Beadlock Wheels that provide extra security for off-road driving to Electric Side Steps for easier access, there are numerous ways to personalize your vehicle to match your style and needs.

Conclusion

The Complete G550 4×4² Portal Axle Conversion for Mercedes G-class W463 is an extensive upgrade that significantly enhances your vehicle’s off-road performance and aesthetics. Whether you opt for the portal axle conversion, the 4″ lift kit, or a combination of both, you can achieve a commanding presence and robust performance akin to the Mercedes G550 4×4². With straightforward installation and minimal additional modifications, this kit is an excellent investment for any serious G-wagon enthusiast. Enhance your driving experience and take your adventures to new heights with the portal axle conversion kit.