FAQ | Installation Notes for Mercedes G-class
Hey guys! We started putting together some frequently asked questions (and answers) on the 2″ Lift Kit, the 4″ Lift Kit, and Portal Axle Kit. Please look at each section below for more information on installing your parts.
If you are an existing customer, and need additional information, please visit the Help Desk to submit a ticket.
2″ Lift Kit for G-class:
Q: I bought your 2″ lift kit with Fox shocks and the Fox Steering Stabilizer Bar Shock. What air pressure should I use for the steering shock?
A: 35 psi
Q: Are the ARB springs specific to the left or right side of the vehicle?
A: Yes. Install the “A” Springs on the Driver Side and the “B” Springs on the Passenger Side.
4″ Lift Kit for G-class:
Q: From Dealer: How do we mount the height sensor on the new radius arm?
“The new radius arms didn’t interfere with any other parts and the install was straightforward. I already did a test drive and everything is OK. One issue we have though is the bracket for the sensor that was mounted to the OEM radius arms…this doesn’t fit the new arm? We’re gonna wait for the adjustable panhard bars to center the axles and do a final 4-wheel alignment. All other things regarding the build have come through very well and our customer is happy.”
A: The Tech measured the angle before installation, then created the same angle with the new arm, and then used a self-tapping screw to attach it to the radius arm.
Q: Are there any codes when running 35″ tires?
A: We have heard of ABS and ESP issues with larger tires. However, our customers have not reported any issues to date. We are using 35″ tires on our project car, and after 6 months, we have not had any ABS or ESP issues. Of course, the speedometer is off by about 15% at 65mph (actual speed is around 75mph).
Q: Are the DTD-spec ARB springs specific to the left or right side of the vehicle?
A: Yes. Install the “A” Springs on the Driver Side and the “B” Springs on the Passenger Side.
Carbon Fiber Mirror Housings:
Q: The glass hits the in the corner of the housing and won’t move further.
A: You may need to sand the inside edges to prevent the glass from rubbing, but these are much nicer than the covers we offer.
Portal Axle Kit – 2nd Generation (General):
Q: Is there a height difference between the Standard and HD portal kit?
A: The height is the same for the Standard and HD Kits, but the HD Kit is 2cm wider on each side. On a separate note, the new 2nd Generation Portal Conversion provides a 5″ lift instead of 4″ lift, and a gear ratio of 1.22:1 instead of 1.16:1. The Manufacturer is using the 1.22:1 ratio now because it is closer to the Mercedes G550 4×4².
Q: What type of oil is used in the portal axles? Is it an 80/W90 or a 75/W90?
A: 80/90 or 75/90 does not matter. Do not use synthetic oil.
Q: How much oil should be in each portal axle?
A: Each portal is about 350 ml
Q: On average, how often should it be changed with on-road use? With a lot of off-road use?
A: The oil change interval depends on the usage. First change after 5000 km then check the oil after the next 5000 km. If the oil looks good there is no reason to change it. Check the oil after excessive deep water usage!
Q: We have come across a problem with disassembling the front axles. I have done research and some G wagons have a C clip to remove to allow the CV to disconnect…but ours do not appear to have a C clip, so we need some instructions on how to disassemble the front axles to fit the new cups. They are not coming apart with anything we have tried. The only information Mercedes gives us is inaccurate for this year. I assume they are press fit with no clips but they just will not come apart.
A: Manufacturer wrote: I know this problem. Sometimes the only way is to cut the CV apart.
Portal Axle Kit – ABS Wheel Speed Sensors:
Q: The physical installation of the portals is complete. The only issue now is with the wheel speed sensors. On acceleration, ESP system shuts down throttle response and the car goes into limp mode. On braking, the ABS pump pulsates the brake pedal from a normal controlled stop. In order to read data from the sensors, the vehicle was sent to the Mercedes Dealer. This is the information they relayed:
- The spacing has been set to factory specifications.
- We are getting consistent readings from all 4 sensors.
- The rear wheels are reading 2 MPH behind the front wheels.
- The front wheels are matching the data from the Output Shaft Speed Sensor.
- The margin of error for wheel speed sensors needs to be within 0.5 MPH.
The only thing that has not been checked is the teeth count of each tone ring. I will begin disassembling each portal tomorrow to inspect tone rings and count teeth to look for inconsistencies. However, I am unsure this action will help, as a mismatched tone ring would cause incorrect readings that would change proportional to speed. The Mercedes Dealer said the back sensors are reading 2 MPH behind — regardless of overall vehicle speed.
A: Mercedes use different sensors. The older cars up to 2006 use simple magnetic pic ups. From 2007 they use active sensors. Make sure you have the right sensors. If they are active sensors you have to use the sensors with the red O-ring on the right side and the black O-ring on the left side. This is important. If the car is using the active sensors, you can also use the original Mercedes sensors with an adapter. Let me know if you need such adapters. First check the teeth on the tone rings and make sure they have the same teeth count.
Q: Portals have been disassembled and the wheel speed issue is hopefully resolved. Found the tone rings in the rear were moving separately then the drive gear and physical evidence of this was found. A separate concern I have is a code present in the transmission control module. I don’t have the code number on hand, but it related to a correlation issue from the transmission output shaft speed sensor to the wheel speed sensors. I am aware the ratios of the portals is set up with the speed sensors to mimic stock values, but wouldn’t this change with tire size? If a correlation between transmission output sensor and wheel speed sensor is needed, tire size would affect this value. Is this ratio setup for 35 inch tires or 37 inch tires? My tone rings all have 48 teeth and this count has been verified.
A: I think the portal ratio does not affect the ABS sensors. The tone ring is on the upper shaft and this shaft turns the same speed as before without portals. Nothing measures the speed after the tone ring. If you change the gear ratio or tire size, the speedometer will show you not the actual speed but the electronic does not notice this. The gap between the sensor and the tone ring should be between 0,2 and 0,5 mm. Do not mix the sensors. The sensors on the right are different than the sensors on the left side. I was told by Mercedes that the gap to the sensor should be between 0.7 and 1mm.
Q: The portals have been reassembled with the rear tone rings staked to the drive (upper) gears. Issue still remains. Vehicle has been sent back to the dealer for data readings. Dealership states sensors on the right side of vehicle match, and sensors on left side match: Left Side reading 6 KPH, Right Side is reading 12 KPH. The Mercedes Service Advisor said they can’t accelerate much further than that, as traction control will begin to shut throttle down.
Before portals were disassembled, O-ring colors on sensors was verified and matched positioning stated in previous emails.
I attempted to disable the ABS and ESP only to throw the vehicle into what felt like a deeper and different limp mode. Permanent damage to the ABS module was done and needed replacement and programing.
A: Check the teeth of the ABS rings. If the teeth are the same on front and rear, it must be a failure of the car’s electronics. Nothing else on the portals can cause this problem.
Q: That is impossible. The electronics are fine. All 4 wheels are reading. We compared the rings and they are identical front to back. Tooth count is the same — but the KMH reading is still off. Is it possible that 2 of the sensors we received are the wrong ones or faulty?
A: Install the original sensors with the provided adapters. This must work.
Q: What should the gap be between the ABS wheel speed sensor and the tone ring?
A: The older cars (up to MY 2006) use simple magnetic sensors. From MY 2007-on they use active sensors. With the old style magnetic sensors, the gab should be 0.2-0.5 mm. With the new active sensors, the gap should be 0.7-1 mm.
Q: All error codes were erased. Hydraulics were checked. Fuses were checked. Pressure regulator for brake system is working fine. The OEM sensors were installed with the adapters purchased from Tibus. With the Technician’s computer hooked up to the car while driving, all 4 sensors are reading speed. However, the car still goes into limp mode at 30 mph. Failure codes at all 4 wheels saying no signal received. Tone Rings all have 48 teeth. OEM sensors are installed in the original position (e.g., passenger front) from the factory. Gaps between OEM sensors and Tone Rings:
Pass Front: 0.79
Pass Rear: 0.73
Driver Front: 0.83
Driver Rear: 0.72
A: This is an electronic problem and not a problem from the portals. There are two possible mounting spots for the sensors. If you choose the wrong one the sensor will be turned. Check if the fastening screw at the sensor shows to the same direction as original. If not change the mounting location. May be there is also a failure on the transmission speed sensor. This is all what i can tell you for now.
Q: I used the same position on each portal to install the ABS Wheel Speed Sensors. At 30 mph the vehicle goes into limp mode. Please advise.
A: We used Tibus sensors. You have 2 of the sensors in backwards. Mercedes is the only car we know of that actually has a right and left side to the sensor itself. Looking at the pics above, the Left Front and Right Rear need to be moved to the other hole / turned around.
Q: Can you please confirm how you did the wiring?
A: Black wire to black and white to white. We twist and solder the connection, then cover it with weather proof shrink wrap, and then cover all the wires in nylon wire loom.
Shop’s Question: We have the OEM Sensors and the TIBUS Sensors. We ordered the adapters from you so we could test the longer OEM ABS Wheel Speed Sensors with the portal kit, instead of using the shorter TIBUS Sensors. What is the position for each?
Manufacturer’s Response: If they are active sensors you have to use the sensors with the red O-ring on the right side and the black O-ring on the left side. This is important. Mercedes: 463-540-21-17-64 BOTH FRONTS, 463-540-19-17-64 LEFT/REAR, 463-540-20-17 RIGHT/REAR. Front, Rear, Right, Left, are all important, but the Mercedes Sensor actually has a right and left side to the sensor itself, so it is also important how the sensor is positioned/installed. See the photos above.
Portal Axle Kit – Emergency Brake Bracket Relocation:
We’re assuming, since the kit is made to fit various models, some modification is required. For example, on the G63 and G65, the bracket for the emergency brake cable has to be re-positioned.
Mercedes G-class W463 Dual Shock Conversion:
Q: Is there a dual-shock conversion for W463 models getting the Portal Axle Conversion to look like the Mercedes G550 4×4?
A: Yes, the kit fits the W463 chassis with portals.
Q: Are the dual-shocks height adjustable?
A: Yes. The shock bodies are threaded. The max height increase is 2″.
Q: Will the dual shocks work on the G63 AMG with larger brake calipers and the portal axle conversion?
A: Yes. We have a new adapter for the brake caliper, so the caliper is mounted higher.
Q: Will the dual shock kit also fit vehicles without the portal axle conversion?
A: Yes. The kit fits portals and no portals.
