DAILY 4x4 ‒ GUIDELINES FOR BODYBUILDERS
CHASSIS INTERVENTIONS
Contents
3
– Printed 692.68.999 – 3 Ed. - Base 08-2020
Contents
2.1 CHASSIS MODIFICATION STANDARDS . . . . . 5
2.1.1 General precautions . . . . . . . . . . . . . . . . 5
2.1.2 Special precautions . . . . . . . . . . . . . . . . . 5
2.1.3 Characteristics of the material used in
chassis modifications . . . . . . . . . . . . . . . . . . . . 6
2.1.4 Stresses on the chassis . . . . . . . . . . . . . . 7
2.2 DRILLS ON THE CHASSIS . . . . . . . . . . . . . . . 7
2.2.1 Positioning and dimensions of the holes . . . . 7
2.2.2 Screws and nuts . . . . . . . . . . . . . . . . . . . 8
2.2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.4 Closing holes by welding . . . . . . . . . . . . 10
2.3 RUST AND PAINT PROTECTION . . . . . . . . . 10
2.3.1 Original vehicle components . . . . . . . . . . 10
2.3.2 Added or modified parts . . . . . . . . . . . . 12
2.3.3 Precautions . . . . . . . . . . . . . . . . . . . . 13
2.4 WHEELBASE MODIFICATION . . . . . . . . . . . 14
2.4.1 General information . . . . . . . . . . . . . . . 14
2.4.2 Authorisation . . . . . . . . . . . . . . . . . . . 14
2.4.3 Impact on steering . . . . . . . . . . . . . . . . 14
2.4.4 Impact on braking . . . . . . . . . . . . . . . . 15
2.4.5 Intervention procedure . . . . . . . . . . . . . 15
2.4.6 Verification of the chassis stresses . . . . . . 16
2.4.7 Cross members . . . . . . . . . . . . . . . . . . 16
2.4.8 Reinforcements on the chassis . . . . . . . . . 16
2.4.9 Modifications to the transmissions . . . . . . 17
2.5 REAR OVERHANG MODIFICATION . . . . . . . 17
2.5.1 General information . . . . . . . . . . . . . . . 17
2.5.2 Authorisation . . . . . . . . . . . . . . . . . . . 18
2.5.3 Shortening . . . . . . . . . . . . . . . . . . . . . 18
2.5.4 Lengthening . . . . . . . . . . . . . . . . . . . . 18
2.6 INSTALLING THE TOW HOOK . . . . . . . . . . 19
2.6.1 General information . . . . . . . . . . . . . . . 19
2.6.2 Precautions for installation . . . . . . . . . . . 20
2.6.3 Tow hook for trailers with central
axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6.4 Observations on payload . . . . . . . . . . . . 24
2.6.5 Increase of towable weight . . . . . . . . . . . 24
2.6.6 Nameplates . . . . . . . . . . . . . . . . . . . . 24
2.7 ASSEMBLING AN ADDITIONAL AXLE . . . . . . 25
2.8 MODIFICATIONS TO THE DRIVELINE . . . . . . 25
2.9 WORK ON SUSPENSIONS . . . . . . . . . . . . . 25
2.10 MODIFYING THE ENGINE AIR INTAKE AND
EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . 26
2.10.1 Intake . . . . . . . . . . . . . . . . . . . . . . . 26
2.10.2 Engine exhaust (only Euro III) . . . . . . . . 27
2.11 MODIFYING THE ENGINE COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.12 MODIFICATIONS TO THE
HEATING/CONDITIONING PLANT . . . . . . . . . . . 28
2.12.1 Installing an additional heating
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.12.2 Installing an air conditioning system . . . . . 30
2.13 BODYWORK INTERVENTIONS . . . . . . . . . 31
2.13.1 General information . . . . . . . . . . . . . . 31
2.13.2 Interventions on chassis cab vehicles . . . . 32
2.13.3 Protection of the vehicle occupants . . . . . 34
2.13.4 Steering column adjustment . . . . . . . . . 35
2.14 CHANGING TYRE SIZE . . . . . . . . . . . . . . . 35
2.14.1 Requirements . . . . . . . . . . . . . . . . . . 35
2.15 WORK ON THE BRAKING SYSTEM . . . . . . 36
2.15.1 General information . . . . . . . . . . . . . . 36
2.15.2 Brake pipe . . . . . . . . . . . . . . . . . . . . 36
2.16 ESP (ELECTRONIC STABILITY
CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.16.1 Derating of the ESP system . . . . . . . . . . 40
2.16.2 Variation of GVW . . . . . . . . . . . . . . . 40
2.16.3 Wheelbase variation . . . . . . . . . . . . . . 40
2.16.4 Modification or replacement of
suspensions . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.16.5 Modification or replacement of the
stabilizer bars . . . . . . . . . . . . . . . . . . . . . . . . 41
2.16.6 Tyre changes . . . . . . . . . . . . . . . . . . . 41
To Next Page
Loading...
Need help?
General
