2004 4x4 T1N Sprinter Overland Camper

[luthj]

Fernweh (fɛʁnve)

Asking $70,000USD. Open to offers. Not all accessories/tools/equipment need be included. Can be made mostly turn key for travel with tools and gear.

Over 10 years ago we decided to build our own ideal full-time overland travel vehicle. Available options were too large, too heavy, or simply too expensive. We focused on usability and capability. Packing as much as feasible in a 19ft long package. Off-grid AC, heat, hot water, a shower, storage, a full sized bed, ride comfort, and real triple locked 4x4 capability. All with an efficient diesel powerplant, with 16mpg lifetime average.

After years roaming from Canada, Aus, NZ, and Mexico in Fernweh, we returned to North America. We were planning to spend a few years exploring Central and South America. However plans changed when we decided to add a 3rd member of our family. So Fernweh needs to go to his next home while we plan a replacement. The thousands of hours of sweat equity we put into him, has made a truly one of a kind vehicle for overland travel. After thousands of amazing nights with us, its time for a new home.


A one of a kind overland campervan:

• Base vehicle: 2006 Dodge (Mercedes) Sprinter Super High Ceiling
• Wheelbase: 140”
• Engine: OM647 2.7L I5 Turbodiesel
• Weight class: 2500 (316CDI in rest of world)
• Factory GVWR 8700lb
• As built GVWR ~9400lb
• As-built wet weight (food, 2 passengers, gear, food etc) 9100-9200lb
• Approximate weight distribution is 5,000lb rear, and 4000lb front
• ~240k miles on engine/chassis. ~40k miles on 4x4 conversion. Front and rear axle/suspension fully rebuilt at that time
• Extensive and complete maintenance records from our ownership. Trans was overhauled 40k ago.
• No DPF/SCR, will happily run on high sulfur diesel fuel
• Located near Tucson AZ - may consider delivery for additional cost
• 4 seasons plumbing
• Excellent ride on and off-road
• Simple to work on. Minimal electronics, and fairly open engine bay.

Factory Options: Towing package (7 pin connector, integrated lights/brake driver, and hitch), air conditioning.


Aftermarket additions:

• Kenwood CD player with Aux in, matching speakers in headliner. Wires run to back for rear speakers if desired.
• Power/remote locking Aftermarket fobs included, factory actuators used. Door locks need torn down for lubricating as rear door and drivers door locks are sticky with remote locking.
• Exterior is mostly factory paint with Blue Monstaliner applied over. Due to primer failure of the factory paint, extensive touch ups have occurred to varying level of success. Rust is minimal, and any that starts was dealt with quickly. During the occasional winter use, chassis and running gear is/was sprayed with fluid film beforehand.
• Custom Steel front bumper with 2” receiver and harness for 8klb winch. Winch in cradle (front/rear usage) can be included with the sale. Bumper has been reinforced with brackets to chassis rails.
• RH rear door has carrier for 2EA maxtrax installed.
• LH rear door has a carried with full sized matching spare tire.
• Both rear doors are limited to 90 degrees opening.
• Knoedler Air Chief front seats. 6” travel air ride, dual adjustable lumbar. Dual adjustable armrests, and adjustable headrest. Passenger seat swivels. Seat belts mounted to upper seat base for comfort. NOTE: Belt mounting has not been pull tested IAW NHTSA requirements. USED AT OWN RISK.
• Fiamma Eagle self-supporting electric awning. Manual drive gearbox has failed and been disabled. Can be replaced if desired. Color matched to vehicle and mounted over passenger side.

 

[luthj]

4WD conversion

• Custom based on GM 2500 IFS and Express rear axle.
• Selecetable AWD or 4x4 locked center diff (dual mode transfer case)
• Front and rear air lockers
• 245/70R16 tires (less than 2,000 miles on current set, plus spare with 15% tread remaining).
• Wheels are GM 16x6.5 with 8x6.5” pattern. Stock steel from early 2000s 2500 pickups. Large range of aftermarket wheels available to fit.

Rear axle:

• AAM (GM) 9.5” differential, semi float, 6,000lb GAWR.
• Geared to 1:3.723 to match original ratio
• Factory springs, heavy duty sway bar sourced in Australia, which is a factory option.
• Fox 2.0 external reservoir adjustable shocks from Vancompass. Valved for the vehicle's weight.
• 8 bolt GM wheel pattern matches front. Matching spare mounted to rear door.
• Vented discs (double mass and area of factory). ARB air locking differential installed with dash switch.
• Factory ESP/ABS is retained.
• Ebrake functions, but does not hold quite as well as the factory unit. Could possibly be improved with adjustment.
• Lifted approximately 3.5” from factory. Will accept a 29.5-31” tire. Some light clearancing of the front wheel wells may be required for a 31” tire.
• Track width increased about 3.5” from stock
• Custom front and rear wheel arch/mudflaps.
• Fuel tank shifted back approximately 10” to clear transfer case. Front mounting strap needs to be adjusted (currently in a “temporary” solution) which can be done before sale.

Front axle:

• Custom IFS based on GM 2500/3500 system (suburban 2500 donor).
• Subframe is custom, upper control arms are Ford F150 gen 1.
• Vented discs, larger than factory.
• Sway bar from donor installed.
• ARB locker to match rear installed.
• Front axle actuator is wired and working. Improves fuel consumption and allows operating in 2LO if desired.
• Subframe must be dropped partially to replace steering rack (rack was new about 60k miles ago). Factory steering rack is retained.
• Total travel is about 8”.
• 3.0 fox external reservoir coilover shocks with dual adjusters. Spring preload is adjustable to change ride height or for load.
• Spare CV shafts are available with the sale, currently in storage in northern Arkansas.
• Factory ESP/ABS is retained.
• Aluminum trans and subframe skid plates installed.

Transfer case:

• NP242D
• Chain driven transfer case.
• Has 2HI, 4HI-part time, 4HI-full time, and 4LO.
• Low range ratio is 2.7:1.
• 4HI-full time has a center differential, and is an AWD mode, suitable for high traction surfaces such as pavement or smooth rock.
• Chain is 1.25” wide. Upgraded with 6 pinion planetary reduction gearset, and includes 32-spline input shaft, and slip yoke output.
• Sourced from a V8 dodge durango.
• A spare transfer case (diassembled) is included with sale (would need picked up in Northern Arkansas where it is in storage.
• Lights on the dash for indication, low range switch needs remounted to provide indication for that gear.
• Cable shifter is mounted beside the drivers seat on the floor.

Transmission:

• Factory NAG1/722.6 five speed.
• Modified with jeep main case and adapter housing to accept married transfer case.
• Valve body, bellhousing, TC, and internals are identical to factory.
• Transmission received a refresh with full inspection and new wear parts as required during 4x4 conversion.
• Spare transmission internals, TC, and valve body parts included, and stored in northern Arkansas.
• Custom rear transmission mount based on Jeep wrangler isolator.

Driveshafts:

• Custom front and rear.
• Rear is large diameter single piece aluminum shaft.
• Rear has some vibration from this shaft above 68mph. May need balancing or adjustment.
• Front has some minor vibration with front axle when engaged over 60mph. Will resolve with differential angle adjustment, which can be done before sale.

 

[luthj]

Engine:

• Mostly factory. Was GDE tuned for about 100k miles. Tune has been removed, but programmer included with sale.
• Modified double sized oil cooler.
• Head and injectors were new 10k miles ago.
• Extensive maintenance records included. Newer radiator, fan clutch, belts, pulleys
• Upgraded to OE 200A alternator.

Upfit:

• Insulated with closed cell spray foam, and thinsulate. The floor is insulated with ½” EPS foam board.
• Front 300W LED light bar above windshield. Rear and side LED light bars in the 20W range. 2W need-to-pee light below the slider door.
• Dometic compact portable toilet in cabinet under the bench seat.
• Permanent bench seat with hinged base for access to electrical and storage. Dual lap belts anchored with grade 8 hardware through floor. Folding/swivel table behind galley, folds out to ~24” wide.
• Driver and passenger have Knoedler air ride seats with custom padded covers, and headrests. Passenger side swivels.
• Onboard Viair compressor with 3 gallon tank. Front and rear quick connects for airing tires etc. Air is needed for differential lockers.
• All wood coated before install.
• 3/16” plywood and plastic wall panels, covered with vinyl wallpaper.
• Floor is sheet vinyl in the front. Factory black plastic in the rear. Cab is factory vinyl floor mat. Hole at drivers foot has been patched. Front floor has ¾” neoprene close cell foam insulation below it.
• Drivers doors sound dampened with thinsulate and open cell foam.
• Drivers/passenger windows tinted with 3m crystalline tint (95% opacity).
• Tern Overland windows in rear, except drivers rear door, which has a second acrylic pane added.
• Maxxfan deluxe - roof vent fan

Galley:

• Welded aluminum with custom ultra high volume utilization aluminum bin/drawers.
• Sink with folding faucet and lid.
• 2 burner True Induction 1800W induction cooktop inset.
• Vitrifrigo 110L fridge/freezer. Heavily modified with exhaust fans, custom dual zone controller, and internal circulation fan, as well as extra insulation.

Communications:

• Starlink full sized flat mount (Gen 3) dish mounted on roof (can be removed for taller individuals, or needs a ladder)
  • Quick connect coupler on cable allows moving dish.
  • Can be used in motion
  • Converted to DC power
  • Starlink router is not used, but can be included.
• Wifi 6 router with custom firmware. External and internal antennas
• Cellular booster with external high gain antenna (powered).
  • Antenna is mounted to rear of solar panels, and can be tilted up for better gain.
  • Cradle is in LH vertical cabinet
  • Router can be configured to tether phone (cannot tether phone and starlink at the same time) Another router product could be used instead for this.
  • Original lower gain flat-mount antenna is on roof, and can be connected instead.

Base cabinetry:

• ½” plywood and poplar framing, attached with rivnuts and bolts to chassis.
• Espar D2 diesel air heater mounted under passenger seat. High altitude kit installed. Controlled by Eaststart controller mounted above cab. Remote temperature sensor installed. High altitude pump installed.
• Rear Scirroco fan mounted above bed. Front Caframo fan mounted above galley.
• Lighting is LED. Light strip above galley on its own switch. Main lighting on a blue sea dimmer, with front/rear switches. Red/white reading light above bed.

Bed: 74x50” with insulated window flare. 7” mattress can be reduced in height by removing topper layers.




Water system:

• 40 gallon fresh water under bed.
• Dual 10" canisters accept standard filters (0.5 micron carbon and 40 micron are my choice)
• 5 gallon isotemp hot water tank (700W 120VAC, coolant via Espar D5, or engine).
• ~12 gallon gray tank mounted under sliding door, drain fitting and manual valve aft of sliding door opening.
• Both tanks have ultrasonic level gauges. They can be a bit unreliable if the van is off level. Both can be swapped to float style if desired.
• Gray tank is heated by D5 coolant loop, as is shower floor, and all drain plumbing below the van.
• Fresh fill is at eye height, inside the right rear door, and is gravity type.

Showers:

• In floor mounted shower pan in central standing area.
• Custom snap-in curtain, with quick attach fittings in ceiling.
• Mixer and quick connected mounted to front of galley.
• A mixer with quick connect is located inside the rear doors.

Electrical:

• Outback 3kw inverter
• Outback 60A MPPT solar controller
• MATE system monitor with Shunt and flexnetDC. MATE monitoring display mounted on panel above front cab.
• 560AH 12V LFP battery bank (custom built) mounted under rear floor near AC outdoor unit. Insulated and heated, good down to about -10F. Orion JR BMS, with diagnostic connector under bench seat. Can supply 400A continuous if required. Can boost/jump start engine battery.
• Alternator direct charging good for 1.2kw+ continuous when underway.
• 640W rooftop solar in 2p2s configuration.
• Second Victron smartsolar controller with connector at rear bumper. Included are 2EA 130W portable solar panels with harness. Designed to hang from rain gutters on 3 sides of the van, or be deployed if van is in shade.
• 30A shore power connection below rear bumper step

Hydronic system:

• Espar D5-II hydronic diesel fired coolant heater. High altitude kit installed. Easystart Timer controller mounted above cab for diagnostics and control. Easystart also controls D2 air heater. High altitude kit installed.
• Isolated from engine loop by a heat exchanger.
• Expansion tank located near hot water heater under the bed.
• A custom controller and dual pumps allow the loop to the following.
  • Transfer heat from engine to heat hot water.
  • Preheat engine for cold weather starting. Use the D5 to heat water.
  • Use the D5 to provide antifreeze of the tanks/plumbing under the van.
• This is done via pushbutton from a custom controller, with a display mounted above the foot of the bed.

AC System:

• Midea 10,000BTU U window unit as base. 120V input, inverter drive motors, for low noise and variable output. 200-750W input power depending on setting and temperature.
• Split in half with enclosures made.
• Indoor unit mounted above bed.
• Indoor half has a modified drain pan to allow parking up to 5 degrees off level left/right.
• Outdoor half enclosed and mounted where the spare tire is typically installed.

Miscellaneous:

• A wide range of spare parts and equipment can be included in sale.
• Sensors, gaskets, hoses, injector, filters, etc.
• BMS Software, firmware/code for custom controllers, etc
• Portable Toilet
• XPLR Outfitters window covers (front three windows, gray interior, reflective exterior).
• Shower curtain with quick release fittings and magnets

Included at asking price:

• 8,000lb winch with synthetic rope on portable 2” receiver carrier (wired front and rear quick connects)
• Star/Xentry C3 multiplexer and virtual machine image (factory level diagnostics)
• Starlink Gen 3 dish (router and power supply included)
• Can include some recovery gear

Clean Oklahoma title in my name. Preferred payment methods are cash, meeting at a local bank, wire transfer.

Contact via PM On Expedition Portal, or by email at 2004fernweh at Gmail.com

Build and travel documented extensively:

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Sprinter 4WD Conversion Idea, GMT-800 IFS.

Greetings and happy new year. After pursuing several other avenues, I have narrowed in on a 4WD conversion approach for my 2004 T1N sprinter. The Sprinter presents some unique challenges. It is a unibody, and uses McPherson strut front end. Instead of coil springs, it uses a transverse...

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As I am nearly at the conclusion of my 2 year build out, I thought it would be fun/useful to cross post some of my sprinter build out over here. A lot of the little details are available in the build logs here. http://sprinter-source.com/forum/showthread.php?t=41215...

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More Photos of interior to follow.

 

[luthj]

 

[luthj]

 

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[luthj]

 

[luthj]

Google Photos link with all the photos, as Expo doesn't always load them.

Van Listing · Oct 13 – 22 📸

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