Motobueno said:
Mike what are the fed rules you mention.If I do my own conversion do they apply?
Thanks Tom
It's a little complicated (OK, so that's an understatement), but the essence of it is that the manufacturer has to make the vehicle conform to all of the NHSTA, EPA and DOT regulations in effect. The regulations cover everything from emissions to color of taillight lenses. A Sprinter van would be in this classification.
The alternative is to make an "incomplete vehicle," which is then given to someone for final finishing. A Sprinter cab-and-chassis unit fits in this category. The secondary manufacturer's additions (like the truck body) has to also meet all of the regulations AND cannot--without great difficulty--undo any of the things the primary manufacturer already got certified.
Thus, when a company decides to do an axle swap to make a 4x4, they theoretically have to submit the paperwork to demonstrate that the change didn't do anything to the vehicle's compliance with the regulations.
On the other hand, changes of this sort are made all of the time to off-roaders. Wheel and tire changes, for example; bumpers; tire carriers that block lights, etc. As a private owner, you can modify your vehicle in whatever ways you believe you can get away with under your state laws. It might, however, be a trickier issue if you made a change, sold the truck, and then the truck crashed because your modification had failed. A lot of what is involved is liability in case things go wrong. The federal approvals are a considerable protection and companies that "undo" them could open themselves up to liabilities if sued.
So, short answer . . . probably not a problem for you if you still meet state requirements, maybe a problem if you start selling kits to do modifications, probably a big problem if you start selling Sprinter 4x4s to all comers.
One last note. Be sure to remember how easy it is to get the Sprinter's computers in a funk. The reason we don't have lots of 4x4 Sprinters running around already is likely because of the difficulties in making everything run right after the conversion.