Body assembly guidelines Volkswagen Nutzfahrzeuge The LT

Body assembly guidelines Volkswagen Nutzfahrzeuge 

The LT 

The following pages contain technical guidelines for custom body manufacturers/ coachwork specialists for 

construction and assembly of custom body-related parts and conversions. 

The body assembly guidelines should be strictly adhered to if modifications are made with the intention of 

doing so. 

Included in the Volkswagen body assembly guidelines are also the body dimension plans for our 

commercial vehicles Crafter, Transporter T4 and T5, Caddy and LT. These can be installed in 3 formats (TIF, 

DXF, IGES) for CAD programs and as PDF files. 

Advice: If further technical queries about the series production vehicle arise over and beyond these 

guidelines, please contact your local conversion expert at your importer. 

Volkswagen Nutzfahrzeuge 

Brieffach 2965/5 

Postfach 21 05 80 

D - 30405 Hannover 

Fax. +49 (0)511 / 7 98 - 85 00 

Online contact: http://www.vwn-aufbaurichtlinien.de/de/kontaktformular 

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the 

decisive source of up-to-date data on body guidelines 

http://www.vwn-aufbaurichtlinien.de 

Data status October 2009

Numerous guidelines are to be adhered to, when chassis is to be transported on their own axles: 

• Wheel cover 

• Ballast weight for braking 

• Lateral starting protection 

• Lighting equipment 

These parts are neither developed nor on-stock, thus making the transport on own axle unnecessarily expensive. For this 

reason, the self-pickup of chassis is no longer possible. It is recommended to deliver the chassis by rail or truck. 

Note: Subject to errors and technical amendments. The electronic version of the body guidelines is the decisive source of up-to-date data on body guidelines (online body 

guidelines). Data status August 2007

For attaching a loading tailboard, it is required to consider the following instructions: 

• The permitted rear-axle load must not be exceeded. 

• Consider minimum front-axle load (i. e. 30% of the total vehicle weight). 

• Check the stability. 

• Calculate the load distribution including all extras. 

• If required, shorten attachment length and rear overhang. 

• Guide subframe as far as possible to the front and realise a force-locked connection with the chassis frame. 

• Standard box-type delivery vans require no subframe. 

• A stabilizer bar is necessary for the front and rear axle. 

• If possible, use only hydraulic supporting devices. Do not lift the vehicle with the supporting device (chassis may 

be damaged) 

• Load distance max. 500 mm 

• Security 

The regulations for the prevention of industrial accidents and the EC Machinery Directive are to be adhered to. 

Check for underrun protection and lighting devices. 

• The standard vehicle can be provided ex-works with the required extras item 1.3). 

Vehicles with double cab may only be provided with a loading tailboard in special cases. The mounting is only permitted 

with the permission of Volkswagen AG. 

Maximum load-carrying capacity and profile 

dimensions: 

Models WheelbaseLifting 

Minimum 

(mm) power dimensions 

to n KN Subframe 

side rail* 

LT 28-chassis 3.000 

3.550 


3.550 

4.025 


4.025 

LT 28-box-type 3.000 

delivery van 3.550 



3.025 



5 

5 

5 

5 

5 

7,5 

7,5 

3 

3 

3 

3 

3 

3 

3 

80 x 45 x 3 

80 x 45 x 3 

80 x 45 x 3 

80 x 45 x 3 

120 x 50 x 4 

120 x 50 x 4 

140 x 60 x 5 

- 

- 

- 

- 

- 

- 

- 

The specified minimum dimensions refer to normal operating conditions and applications without overhang extension.

For example, when working with a lifting hoist, the entire vehicle may be lifted on 4 hydraulic pillars -the wheels lose all 

contact with the ground. Due to the heavy weight of the front of the vehicle, this causes impermissibly high tension in the 

longitudinal frame members in the area of the front support. 

A reinforcement of the chassis frame is essential for such applications. To this end, fit a mounting frame through the rear 

wall of the cab under the base of the seats and secure this with an additional console and a bolt connection. A suggestion 

as to how this can be implemented can be given on request by the responsible department. 

An additonal battery as per PR-No. 8FV (location underbase of co-driver's seat) is not possible with this configuration and 

also for the LT 46. 



When laying out the loading crane attachments, it is required to observe - apart from the necessary stability - the 

connection between loading crane and chassis (item 3.4). 

Loading crane and vehicle attachment are to be arranged in such a way, that the permitted axle loads are kept in every 

loading state. 

Loading crane attachment behind the driver s cab 

• Maximum crane-load moment: 25 KNm 

Moments of resistance for mounting-frame side rails: Wx = 45cm3 • 

(45cm3 (profile dimensions according to 

diagram under item 3.3) 

• Determine the flatbed length depending on the loading-crane attachment. 

• Due to the load distribution, it may be necessary to lengthen the chassis. 

• A permission is required for deviating crane attachments. 

• The necessary supporting devices should be hydraulically actuated. 

• Do not lift the vehicle with the supporting device (chassis may be damaged) 

• Crane attachments and supporting devices must neither impair other equipment, modules, units, etc., nor the 

associated functions. 

• Loading crane attachments must meet the requirements of the regulations for the prevention of industrial 

accidents and the EC Machinery Directive. 


guidelines). Data status December 2007

According to article §51b. of the German motor vehicle traffic regulations (STVZO), vehicles with a width of more than 

2,100 mm must be provided with parking lamps when they are to be used in the Federal Republic of Germany. 

As standard, all chassis and chassis with flatbed attachment are not provided with parking lamps (standard vehicle width 

1,922 mm and 1,990 mm). 

In the LT delivery program, the tipper with single and double cab as well as the LT46 Pick up with single and double cab 

exceeds the pre-set vehicle width (standard width: 2,120 mm). At these vehicles, parking lamps are assembled in front on 

the side on the cab roof. In addition, the outside chambers of the 6-chamber lamps at the vehicle rear are designed as 

parking lamps (series equipment: PR-No. 6S1). 

When ordering a chassis that is to be used for an attachment with a width of more than 2,100 mm, it is required to order 

also back and front parking lamps (PR-No. 6S1). 

If the intended vehicle width exceeds 2,100 mm and if the rear parking lamps are to be mounted by the attachment 

manufacturer, it is only possible to order parking lamps that are to be mounted on the roof in front (PR-No. 6S3) (SBBR 

lamps can be left out at PR-No. 8SZ; preparation SBBR lamp). 



According to article §51a. of the German motor vehicle traffic regulations (STVZO), vehicles with a length of more than 6 

m must be provided with yellow side marker lamps and lateral reflectors. 

In the LT delivery program, only the chassis with long wheel base exceeds the pre-set vehicle length. 

If required, all standard vehicles are to be provided with reflecting side marker lamps. 

All chassis with long wheel base are prepared ex-works for side marker lamps (wiring harness). The attachment 

manufacturer is responsible for installing side marker lamps. 



According to article §54 of the German motor vehicle traffic regulations (STVZO), multitrack vehicles must be provided at 

the long sides with additional flashing indicators to be mounted in the first third of the front section. 

If the permitted total weight is more than 3.5 t, the light intensity of these flashing indicators must lie between 50 cd (min.) 

and 200 cd (max.). All vehicles with a permitted total weight of less than 3.5 t are to be provided with small lateral flashing 

indicators (5W). All vehicles with a total weight of more than 3.5 t are to be provided with large lateral 

flashing indicators (21W). 

Minimum visual angle ranges are pre-defined for mounting of lateral flashing indicators. As a result, it is mandatory to 

mount various flashing indicators, depending on the attachment width: Small lateral flashing indicators 

• Width up to 2,100 mm 

Large lateral flashing indicators 

• Width between 2,101 and 2,200 mm 

Large lateral flashing indicators with adapter 

• Width between 2,201 and 2,500 mm 

Due to the confinements imposed by vehicle length (cf., item 3.13), permitted total weight and attachment width, the 

required combinations of flashing indicators/marker lamps are already pre-defined for standard vehicles. Only attachment 

widths of more than 2,200 mm require large lateral flashing indicators with adapter (can be ordered, PR-No. 8F8). 



According to EU Directive 76/756 EEC and article §54 of the German motor vehicle traffic 

regulations (STVZO), motor cars that are to be used in the Federal Republic of Germany must 

be provided with mirrors. These mirrors must be designed and installed in such a way to permit 

the driver to look backwards and sideways - also if a trailer is hooked up to the vehicle - so that 

he or she is capable of observing the traffic. 

As standard, all LT-model are equipped with an interior mirror and a exterior mirror - for a max. 

attachment width of up to 2,150 mm. 

For attachment widths between 2,150 mm and 2,400 mm, exterior bracket mirrors are available 

(normal/large bow). 

Availability of LT exterior mirrors 

(see also Sales Manual): 

• Standard mirror (serial) - attachment widths up to 2,150 mm 

• Bracket exterior mirror, normal (standard dump truck and LT 46 chassis) - attachment 

widths between 2,151 mm and 2,300 mm 

Bracket exterior mirror, large - attachment widths between 2,301 mm and 2.400 mm 

• 



The attachment manufacturer has to ensure that 

• it is possible to mount the largest permissible tyre size, 

• the distance between tyres and mudguard or wheel housing is sufficient, even with mounted snow chains or 

antiskid protection chains and with full single-sided or two-sided compression. Consider the dimensions that are 

specified in the chassis drawings. 

LT wheels/tyres/allocation 

Disk wheel Tyre 

LT 28 5 1 / 2 J x 15 H2 

(press-in depth 

195/70 R15 C 104/102 R 

(Special equipment) 

83 mm) 

6 J x 15 H2 225/70 R15 C 112/110 R 

LT 35 6 J x 15 H2 225/70 R15 C 112/110 R 

Twin tyres at the back 

LT 46 5 1 / 2 J x 15 H2 

(press-in depth 

115 mm) 

195/70 R15 C 104/102 R 



The standard spare-wheel positions, depending on car-body design and motorization and according to the following 

overview/assignment matrix, are shown in the box-type delivery van and chassis drawings. 

Assignment - LT spare wheel/spare wheel support 

Car-body design Model Engine PR-Nr. 

1BO 1B1 1B2 1B5 1B9 

Box-type delivery van LT 28/35/46 Diesel o x - o - 

Chassis with cab LT 28/35 Diesel o o x - o 

LT 46 Diesel o x - - - 

Chassis with double cab LT 28/35 Diesel o o x - o 

LT 46 Diesel o x - - - 

x = Standard production type 

o = Special equipment 

PR-No. 1B0 = Without spare wheel support (enforces "Without spare wheel (PR-No. 1G0)") 

PR-No. 1B1 = Normal spare wheel support - behind the rear axle, below the frame 

PR-No. 1B2 = Spare wheel support for double cab and driver s cab - on the right side rail 

PR-No. 1B5 = Spare wheel support in the interior - behind the wheel housing 

PR-No. 1B9 = Spare wheel support for double cab and driver's cab - provisionally attached on the right side rail. The 

attachment manufacturer is responsible for the final attachment according to official regulations (easy access, simple 

operation, dual protection against losing) ("1B9" enforces: "Without flatbed bottom frame (PR-No. 5HA/5HJ)") 

In case of deviations from the ex-works spare-wheel attachments (this does not apply to fastenings at the 

attachment), it is required to ask the responsible department for a permission 



According to EU Directive 70/221 EEC and article §32 b. of the German motor vehicle traffic 

regulations (STVZO), motor cars at which the distance between rear limitation and rear axle is 

more than 1,000 mm and which have, in unloaded condition, a headroom of more than 700 

mm (applying either to the total width of the rear chassis or the main car-body parts) above 

lane, must be provided with an underrun protection. 

At all LT vehicles, the main car-body parts lie less than 700 mm above lane. For this reason, 

standard vehicles require no underrun protection. As standard, all LT 46 chassis models 

(with/without flatbed) are equipped with a rear underrun protection. 

The maximum distance between the rear edge of the attachment and the main car-body parts 

(at the chassis, this applies to the bulb retainers) is 400 mm. If 400 mm are exceeded, the 

attachment manufacturer is obliged to construct and install an underrun protection 

corresponding to the relevant EU Directives. 

For this purpose, it is recommended to use the screw connections at the frame that are 

provided for the trailer coupling. 



According to EU Directive 89/297 EEC and article §32 c. of the German motor vehicle traffic 

regulations (STVZO), motor cars whose permitted total weight exceeds 3.5 t and whose main 

car-body parts have a headroom of more than 500 mm above lane, must be provided with 

lateral protectors, if these vehicles are to be used in the Federal Republic of Germany. 

Excluded from this regulation are tractive units, driven machines and special vehicles whose 

operational purpose cannot be fulfilled by the lateral protectors. 

As standard, all LT 46 flatbed models are provided with lateral protectors. At the LT chassis 

(cab/double cab without flatbed), no lateral protectors are mounted. The lateral protectors must 

be constructed and installed by the attachment manufacturer relating to the attachments 

according to the relevant EU directive. 

If lateral protectors are to be installed subsequently, the following instructions apply: 

• Component parts, such as battery box, air receivers, petrol tanks, lamps, reflectors, 

spare wheels and tool boxes, may be installed if the prescribed distance dimensions 

are kept. Brake, air or hydraulic lines and other parts must not be attached to the 

lateral protector. 

• Function and accessibility of all equipment, modules, units, etc. of the vehicle must 

not be impaired. 



There are clear instructions available for handling vehicles with longer service lives (see manual Service Technology, 

volume: Inspection and Maintenance, item 3.2.4, Storage of Brand-New Vehicles). These instructions are defined by the 

customer service and are to be adhered to. Observe the following note when handling the tachograph: If the acceptance 

stamp is older than six months, the tachograph should be re-submitted to an acceptance test. 



General information 

• The attachment of the trailer coupling must correspond to the specific directives of the relevant country. In the 

Federal Republic of Germany, standard DIN 74 050 has to be complied with. 

• Consider free-space dimensions*. In the Federal Republic of Germany, standard DIN 74.058 has to be complied 

with. 

• If deviations from the German regulations for the prevention of industrial accidents (UVV) are necessary, it is 

required in the Federal Republic of Germany to request an import certificate ["Unbedenklichkeitsbescheinigung"] 

from: Berufsgenossenschaft für Fahrzeughaltung [German Trade Co-operative Association for Matters 

Associated with Car Owning], 22757 Hamburg (phone +49 [0] 40/38 10 91). 

• If trailer couplings are to be installed subsequently, only products which have been approved by us and original 

Volkswagen end cross-members may be used. Attachment points are available at our end cross-member and/or 

side rail. 

• The size of the trailer coupling is defined according to the D-value. 

The size of the trailer coupling is defined according to the D-value 

D = control-shaft value 

mk = permitted total weight of the tractor (motor car) in t 

mA = permitted total weight of the trailer in t 

g = 9,80665 m/s 2 

The permitted trailing load can be taken from the valid sales documents or the guide "Trailer 

Operation". In order to permit the trailers being exchanged in transborder traffic, the distance 

dimension, x, must not exceed 300 mm. 

* If the trailer is extremely low lying or if a special attachment is extremely overhanging, it may 

be prohibited to use a trailer coupling. 

Mouth clutch (can be ordered ex works under PR-No.1D5) 

• Max. distance between the middle of clutch bolt of the trailer coupling and attachment 

end: 420 mm. Keep clearances. 

• 

In special cases, it is permitted to exceed the distance dimension of 420 mm: Max. 

distance 650 mm for vehicles with tiltable attachments or rear attachments. Max. 

distance 1,320 mm, if the headroom between lane and the lower attachment edge is 

at 1,150 mm. A suitable remote control for the clutch must be available. The safe 

actuation of the clutch must not be impaired.

Spherical coupler (can be ordered ex works under PR-No.1D1) 

• Keep clearances. 

• The installation is only permitted at approved trailing supports. 

• It is not permitted to perform the installation only at the underrun protection. Modifications of the underrun 

protection must be arranged with the responsible testing and research laboratory (in Germany: TÜV). 



An operating permit is available for the brake system of the vehicles. This licensing becomes invalid if the brake system is 

modified. Therefore, modifications of the brake system are illegal. 

If it cannot be avoided to perform works on the brake system, e. g. changing the wheel base, the following instructions are 

to be considered: 

• Replace hydraulic brake lines completely. 

• Dimensions of roller laminated tube: 4.75 x 0.7; plastic lines/tubes are not permitted. 

• Mould lines only with a bending fixture 

• Bend radius = 17.5 mm 

• Clean the interior of lines. 

• Keep safety clearance to heat sources, pointed, sharp or moving parts 

• Attachment with plastic loops, max. distance 500 mm 

• Let the ALB controller be re-adjusted by a VW dealer if the weight has changed. 

After finishing works, check whether the brake system is perfectly functioning. 

Retarder 

• If a retarder is to be subsequently installed at the transmission or in the drive-shaft strand, it is required to ask the 

responsible department for a permission. Approvals are not generally given but are basically limited to specific 

vehicle designs and wheel bases. 

The mounting drawings must include the following information: 

• Position of the retarder in the vehicle 

• Drive-shaft angle 

• Length of the drive shafts 

• Due to the additional weight of the retarder, the distribution of weight and adherence of the permitted axle loads 

has to be checked. Check location of the centre of mass of the attachment. Adjust it, if required. 

• Mounting is only permitted at vehicles with sufficiently dimensioned electrical installation (generators and 

batteries with sufficient capacity). Ensure a sufficient ground connection of the retarder. 

• Ensure sufficient freedom of operation. 

• In the drive-shaft strand, attach the retarder only at the bar of the chassis frame using brackets with silent blocks. 

• Protect lines against heat by using an appropriate insulation. The permitted maximum temperature for polyamide 

lines is 80°C. 



Power output of the engine via v-belts 

At the engine, the output can be decreased by max. 10 kW via v-belts, if the available flange points are being used. 

Versions available ex works: 

optional: 

• Power steering pump/steering booster pump, standard 

• 2. Generator, 90 A (PR-No. 8HB) 

• Refrigerant compressor (PR-No. 2AB), operative compressor installed in the vehicle, Sanden SD7 H 15 

(non-controlled) 

• Hydraulic pump as enclosed package (PR-No. 2BD) preparation for installation 

At backfitting of a refrigerant compressor it is important to order the preparation refrigerant compressor (PR-No. 2AC). 

Otherwise you have to assemble the original parts. Differing parts can cause damages (for example, fracture of the 

clamping element). 

Auxiliary drive of standard transmission 

Actuation is realised via the countershaft of the transmission 

Versions available ex works: 

Module PR-Number 

ZSBTransmission without auxiliary drive, standard 0R0 

ZSBTransmission with auxiliary drive 

Countershaft without flange 


Countershaft with flange 


Switch lock for transmission 

Countershaft without flange 


Switch lock for transmission 

Countershaft with flange 

Power take-offs are not available for 2,5l diesel TDI(61kW). 

0R1 

0R3 

0R6 

0R7 

The electronical engine speed govemor (PR-No. 6Y3, 6Y6) is only available for power take-offs (PR-No. 0R6, 0R7). 

Notes:

• The design of the auxiliary drive and the selection of the gear ratio depend on the power and speed (revolutions 

per minute) of the modules to be actuated. 

• Transmission-dependent auxiliary drives may only be switched on/off with the vehicle standing still. 

• Information on max. transmissible torques (Nm) of the individual auxiliary drives can be taken as guide values for 

shock-free and non-oscillating operation. According to DIN 922, the above specifications are based on a 

fatigue-limited gearing layout and a calculated service life of 500 hours. Additionally occurring inertia forces at the 

modules to be actuated are not considered. 

• The gear ratio of the auxiliary drive has to be selected in such a way, that the minimum speed (engine), i. e. 

between 1,000 rpm and 1,200 rpm, is not exceeded if the auxiliary drive is loaded. The output decrease should 

lie within the range of the maximum engine torque. 

• Exposed drive shafts, fan rotors or belt pulleys must be covered. 

• It is not permitted to attach belts or chain drives to the drive shaft or flange of the auxiliary drive. However, if 

exceptions from the above specifications cannot be avoided, the appropriate drawings and data must be 

submitted for approval. 

Dimensions - clutch flange - Auxiliary drive 

a 

ø b ø c ø 

d 

ø e ø f ø 

Number 

of holes 

90 74,5 47 e8 6 2.1 8,0 B12 6 

Technical data/information - auxiliary drive 

• Max. torque decrease for shock-free and non-oscillating operation: Md = 200 Nm 

• Continuous power at engine speed 2,500 rpm: Nmax = 20 kW 

(max. 40 kW, for short time: approx. 3 minutes) 

• Continuous power with engine cooling system with heavy-duty fan and radiator (PR-No. 8Z2): Nmax = 30 kW 

(max. 40 kW, for short time: approx. 3 minutes) 

• Drive speed at auxiliary drive 

MNA = 0,775 x nMot I II III IV V VI VII A1 B1 C1

2,5 l 

TDI 

2,8 l 

TDI 

G 28-5 0R3/0R7 

0R1/0R6 

Additional information on table "Auxiliary drives": 

I 

II Transmission 

III Designation of auxiliary drive 

IV Drive speed (rpm) 

at auxiliary drive nNA = iNA x nMotor 

V Continuous power at auxiliary drive 

VI Max. torque decrease at 

auxiliary drive in Nm 

VII Direction of rotation seen in driving direction 

a) anti-clockwise 

0,775 

0,775 

20/2500 

20/2500 

A1 Distance between rear edge of clutch flange and middle of front axle 

200 

200 

B1 Distance between middle of clutch flange and top edge of chassis frame 

C1 Distance between middle of clutch flange and middle of transmission flange 

a 

a 

639 

745 

131 

127 

100,6 

100,6 



Usually the flatbed must be raised according to the required subframe height. Since the standard flatbed version affected 

here is provided with very high, u-shaped cross-members, it is possible to perform the following procedure: 

The cross-members of the standard flatbed are cut out in the areas the chassis side-rails in such a way, that it is possible 

to fit in precisely the continuous subframes and to connect them to the cross-members by means of welding. (Position of 

subframes exactly above the standard side rails, see illustration below.) Dimensions of subframes and attachment of the 

loading tailboard to be performed according to our construction guideline. 

The attachment of the standard flatbed, which is modified as described, can be performed without changing the chassis, 

however, appropriately longer screws are to be used. The spacing between flatbed cross-member and chassis brackets is 

to be levelled out with shims (bushings). 



General Information: 

• For a perfect connection between chassis and attachment, for all attachments a subframe or a floor panel 

assembly (taking over the function of the subframe) is required (except for self-supporting attachments and 

subframes as a base group). 

• The subframe side rails should lie flatly and following the chassis profile on the upper belts of the chassis frame. 

• The following applies to LT 46 models (twin tyres): 

In the area of the rear axle, the chassis-frame side rails are inwardly offset. The subframe side rails need not 

follow this offset but can be executed continuously straight. Wooden fillets between chassis-frame side rail and 

subframe side rail are not permitted. A bracket attachment, via subframe cross members, is required in the area 

of the rear axle. 

• Subframe cross members are to be arranged above the chassis-frame cross members. 

• For the side rails, use bevelled u-beams or standard u-beams that are generally used for the construction of 

vehicles (no rolled steel sections). Box sections are also permitted. 

• The side rails dimensions result from the moment of resistance (Wx) required for attachment and chassis. See 

diagram 3.3.2. The specified moments of resistance and section/beam dimensions refer to frame side rails that 

are evenly loaded on both sides. 

If several attachments are to be assembled on a chassis (e. g. flatbed and loading tailboard), the greater value of the 

specified moments of resistance must be taken as a basis for defining the subframe. 

Subframe as base group: 

A subframe with continuously running side rails is not required if the base group of the attachment can take over the 

function of the subframe. 

Subframe for reinforcing the side bars in the front-end area of the vehicle: For example, when lifting platforms are 

operated, the entire vehicle may be lifted by 4 hydraulic supports, so that the wheels no longer touch the ground. Due to 

the high weight of the front end of the vehicle, inadmissibly high tensions appear in the chassis side rails in the area of the 

front support. For this reason, it is mandatory to reinforce the chassis frame if this application is planned. This requires to

lead the subframe through the back of the cab to a location under the seat box. It has to be attached with a supplementary 

bracket and a bolted connection. An execution recommendation can be requested at Volkswagen AG, department NV-VS. 

This subframe execution does not permit to install an additional battery (PR-Nr.8FR). 

Material Qualities for Prescribed Steel Subframes: 

The subframe with bracket attachment (force-locking) is to be implemented as St 12.03 or St 37-2. 

Material Tensile strength 

N/mm 2 

Yield point 

N/mm 2 

St 12.03 >360 210 

St 37-2 >360 235 

Subframes that are made of high-strength steel must at least correspond to the stiffness of 

steel subframes. The attachment must be realised with force-locking capability. 

Flatbed truck attachments, aluminium type 

• Adhere to the instructions of the aluminium manufacturers 

• Side rails, plank floor, floor mats and carrying hook conveyors must form a 

self-supporting unit. 

The profile transition at the front ends of the side rails should be gradually realised.

I Box section 

II U-beams 

1 Chassis frame 

2 Subframe 

3 Standard fixing bracket 

4 Console 

If it is required to implement very high side rails or if low total heights of the chassis are to be implemented, the 

u-beam - at locked-force connections - must meet the following specifications: 

• It must be closed as a box 

• It must be nested into each other 

• It must be nested 

As a result, the moment of resistance and the torsional stiffness are increased. Make sure that the transition between 

closed side rail and open u-beam is properly executed. 

Profile dimensions 

The profile dimensions for subframe side rails (open profile), subframes and chassis frames should approximately have 

the same material thickness and flange width. 

Profile height (in mm)

Determine the mounting method depending on the chassis type, attachment and according to the operation purpose of the 

vehicle. Attach the subframe on the fixing brackets (which are available as standard) of the chassis frame. Use shackle 

attachments if additional attachment points are required. Define the number of attachments in such a way that is it 

ensured that the braking and lateral forces are properly absorbed. 

The correct attachment is decisive for: 

• Road behaviour and the operational safety of the vehicle. 

• Operational life of chassis frame and attachment. 

If locked-force connection are used, the side rails must be attached length and crosswise. 

If pre-assembled subframes are used, constructional tolerances of the chassis frame width (max. + 6/-3 mm) are to be 

considered. Compensate for manufacturing related frame bending (max. 6 mm) by using supports. 

Bracket attachment with side rail 

Bracket attachment with cross member 

Locked-force connection, bracket attachment 

• A movement of the subframe side rail in relation to the chassis side rail is possible with restrictions. 

• Perform rigidity strength calculations for each individual side rail. 

• 

Divide up the bending moment according to the moments of inertia.

1 Standard fixing bracket (see chassis drawings for number and dimensions) 



The mounting frame is exclusively used for directly receiving attachments. Only screws are permitted for attaching the 

mounting frame at the chassis frame. The mounting frame needs not to cover the entire chassis frame up to the cab - as is 

the case with the subframe. (see item 3.3.3. Figure: Bracket attachment with cross-member mounting frame) 

The mounting frames does not meet any strength requirements to protect the vehicle chassis. 



When the modified vehicle is brought forward to an inspection or acceptance test, according to EC directive, Brakes, 

71/320/EEC, the centre-of-mass height must be mathematically proved using a loaded vehicle. Bases of calculation and 

permitted centre-of-mass heights can be requested from Volkswagen AG. 

If the centre of mass lies high, provide stabilizer bars and reinforced shock absorbers (if available). If the centre-of-mass 

height exceeds 960 mm at the LT28 / LT35, it is required to use the stabilizer bar at the back (OBC) and reinforced shock 

absorbers. Permitted centre-of-mass height: 1050 mm. If the centre-of-mass height exceeds 1,100 mm at the LT 46, it is 

required to use the reinforced stabilizer bar at the back (OBD). 

Centre-of-mass heights - base vehicle: (empty, including driver with 75kg) 

LT 35 Chassis: h = 780 mm 

LT 35 Box-type delivery van: h = 840 mm 

LT 35 Station wagon: h = 850 mm 

LT 35 Flatbed: h = 805 mm 

LT 46 Chassis: h = 725 mm 

Volkswagen AG does not provide information on the road/braking/steering behaviour of attachments used for loads with 

an unfavourable centre-of-mass position (e. g. rear, high and side loads). The attachment manufacturer is responsible that 

these attachments do not impede the road-holding qualities of the vehicle. 



Driver s cab: 

Functioning, smoothness and free movement of instruments and operating equipment as well as the stability of supporting 

parts must not be impaired by modifications performed at the cab. If the cab is to be built over, the permitted 

centre-of-mass position and the permitted front-axle load is to be considered. 

Roof loads/roof racks: 

Box-type delivery vans and station wagons: 

• Max. 300 kg (vehicles with high roof: 150 kg) if the load is uniformly distributed over the entire roof surface. 

• A stabilizer bar must be installed at the front axle. 

• The roof rack must have at least 5 sustainers (with a roof of 300 kg) or 4 sustainers (with a roof of 150 kg). The 

sustainers are to be evenly positioned. 

• If the roof rack is shorter, the loading has to be reduced proportionally. 

Vehicles with cab or double cab: 

• Max. 100 kg if the load is uniformly distributed over the entire roof surface. 

Note: The installation instructions only apply to box-type delivery vans and station wagons. 

1 Roof rack 

2 Sustainer 

3 Brace 

Roof heightening (plastic roof): 

• Install a stabilizer bar at the front axle 

• 

If roof cladding and roof bow are separated and if no continuous profile frame is possible, additional roof bows 

are required.

Number: 

4 Bow with wheel base 3.000 mm 



Arrangement 

1. behind the driver s cab doors (B-pillar) 

2. in the middle of the sliding door (between B-pillar and C-pillar) 

3. in the middle of the vehicle behind the sliding door (C-pillar) 

4. to 6. between C-pillar and rear pillar 

• The connection between bows and side walls must be laid out in such a way that a locked-force connection is 

ensured (flex-resistant connection of bow and roof chassis). The new roof structure must correspond to the 

standard roof relating to stiffness. The required minimum moment of inertia (Ix) of the roof bows can be taken 

from the following table. 

• Roof height Moment of inertia (Ix), per bow 250 mm 40.000 mm4 400 mm 65.000 mm4 550 mm 86.000 mm4 

These specifications are based on an e-modulus of the plastic roof of 7,000 N/mm2 and a wall thickness of 4 

mm. 

Roof height Moment of inertia (Ix), per bow 

250 mm 40.000 mm 4 

400 mm 65.000 mm 4 

550 mm 86.000 mm 4 

These specifications are based on an 

e-modulus of the plastic roof of 7,000 

N/mm 2 and a wall thickness of 4 mm. 

Notes: 

Rising roof 

• In case of deviations, it is required to ask the responsible department for a permission. 

• Plastic roofs are only suitable to a limited extent for mounting roof lamps. 

• The roof load is limited. 

• If a rising roof is to be mounted, at least two thirds of the original roof surface must be maintained. 

• Do not remove any cross-beams or supporting parts. 

Air baffles: Air baffles on the cab roof may only be attached with retainers at the door frame or at the rear welding flange 

(back wall of roof). Bores in the cab roof are not permitted for attaching components. If other roof attachments (e.g. 

air-conditioning system) are to be installed, it is required to ask for the permission of Volkswagen AG. 



At self-supporting attachments, a subframe with appropriate side rails is not necessary, if the cross members keep a 

maximum distance of 600 mm. This distance may be exceeded in the rear-axle area. 

Self-supporting attachments are to be attached at the chassis over all available brackets (2 screws per bracket). 



• The forces which are induced punctiformly are to be distributed uniformly via a subframe over the entire chassis 

frame. 

• For this purpose, the subframe should lie without torsions over the side rails and should be guided up to the cab 

(procedures according to item 3.3). 

• At a chassis with double cab it may be necessary to shorten the rear chassis overhang. This measure is to be 

controlled on the basis of axle-load calculations. 

• High centres of mass for attachments and net-loads impair the driving and braking behaviour. The chassis can 

be provided ex-works with stabilizer bars/attenuation. 

• Due to the width and length of the attachment, it may be necessary to modify lighting, markings and exterior 

mirror. These modifications are listed under items 3.12 - 3.15. 

• The necessary underrun protection and lateral protection is described in items 3.18 and 3.19. 

Moments of resistance of the subframe side rails for flatbed attachments: 

Model W x /side rail in cm 3 

LT 28 


20 

LT 46 30 

Profile dimensions see diagram, item 3.3. The specified values refer to normal operating conditions and applications 

without overhang extension. 



• When handling trilateral and rear dumping attachments, arrange the spherically seated bearings at the rear end, 

close to the rear axle. 

• Provide guide angles for the relevant spherically seated bearings, so that the dumping bridge is guided during the 

dumping. 

• The maximum inclination angles and dumping bridge lengths can be taken from the axle load calculation, 

considering the maximum external attachment lengths. 

• The pressing support is to be attached on cross members in the subframe. 

• It is recommended to arrange the subframe cross-members over the cross members of the chassis frame. 

• At trilateral dumping attachments, the point of application force of the dumping press is to be set in front of the 

centre of mass of attachment and net weight. 

• Protection If required, the dumping bridge has to be secured against dropping. Take measures against 

unintentional operation. As a visual warning (dumping bridge not in driving position), a control lamp is to be 

connected in the cab. 

• Subframe 

The subframe must be must be continuously designed and be provided with sufficiently dimensioned cross 

members made of steel. Close the rear area adjacent the box and brace it with diagonal cross. Connect the 

subframe with the chassis frame corresponding to the load, according to item 3.3.3. 

• To fix the subframe laterally, weld guide plates in the area of the cross members at the subframe. 

Moments of resistance of the subframe: 

Model W x /side rail in cm 3 



45 

LT 46 60 

Profile dimensions see 

diagram, item 3.3. The 

specified values refer to 

normal operating 

conditions and applications 

without overhang 

extension.

Body assembly guidelines Volkswagen Nutzfahrzeuge The LT

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