Iglhaut Allrad Sprinter: Ultimate Off-Road Mercedes 4×4 Conversion

Transforming A Two-Wheel-Drive Mercedes Sprinter into the Ultimate Off-Road Van

With 15,000 miles on the odometer, Daniel Kuttner’s Iglhaut Allrad up-fitted Mercedes Sprinter has already proven itself on and off road. From cruising the autobahn at 110 mph to crawling the rocks of Moab, this beast has done it all with composure and confidence.

“Allrad” is German for all-wheel drive. The Iglhaut Allrad 4×4 conversion system has transformed this basic two-wheel-drive Mercedes Sprinter into the ultimate off-road van. Your eyes aren’t deceiving you, this beast is rolling on massive 37-inch tires.

The Limits of the Factory AWD System

But before we get too carried away with visions of mud-slinging glory, let’s talk about where the factory all-wheel-drive Sprinter setup comes up short. Straight off the dealership lot, you can get your Sprinter with Mercedes’ standard AWD and traction control, or spring for the optional low-range transfer case. On paper, that sounds rugged. In practice, it leaves much to be desired for those with adventurous ambitions.

Here’s why:

• Modest Low-Range Gearing: The stock low-range transfer case offers just a 1.42:1 reduction—enough for mild dirt roads, but not much help when you’re clawing up a steep slope or picking your way through boulder fields. That ratio simply isn’t low enough to truly multiply torque or control wheelspin effectively on tough terrain.
• Torque Split & Differentials: The system channels most of the torque rearward (65% rear, 35% front), with no locking center diff to really tie the axles together. If traction gets patchy and wheels start slipping, the system’s electronic traction aids step in—but not always with finesse.
• Traction Control Limitations: The 4ETS system uses brakes to limit wheelspin, but when things get seriously cross-axled or muddy, you may find yourself fighting more than forging ahead. In these moments, the system’s interventions often compromise momentum, and excessive wheelspin can leave you digging instead of driving.

In short, the stock Sprinter AWD is solid for gravel roads, snow, or the occasional muddy trail. But if your adventures routinely lead off the beaten path—through deep ruts, loose sand, slick rock, or technical climbs—the limitations of the factory system show their face quickly.

That’s exactly where an Iglhaut Allrad conversion takes things to the next level…

The Iglhaut Story

Let’s start at the beginning. Fritz Iglhaut was a truck driver in the ’50s who had a dream of building his own trucks, a dream shared by two of his four sons, Friedrich and Hans.

They built their first truck in a clay mine after hours. By the ’60s, Fritz and Friedrich had built several trucks and Hans had become a master technician at Mercedes.

The first Iglhaut Mercedes dealership opened in 1965 in Marktbreit, Germany.  The dealership quickly gained a reputation for superior quality and craftsmanship, and a can-do special projects ethos. The business continued to grow, and in 1979, Iglhaut’s automotive fabrication division moved into its own facility.

In 1983, Iglhaut was commissioned to build an all-wheel-drive Mercedes 207D for an alpine hotel owner, which proved to be so good that two more were ordered.

This was the first AWD conversion on a Mercedes commercial vehicle, and led Iglhaut down the 4WD conversion business model they have today.

By 1985, third-generation Michael Iglhaut was a Mercedes-certified automotive technician and working alongside his father, Hans, when an invitation arrived for the Liberty-Raid Rally, which went from Cologne to Khartoum to Cairo.

Hans told his son, “You’re doing this.” With no rally experience and in his own creation, Michael came in Second. This impressive performance helped make Iglhaut a world-renowned name in the off-road community.

Iglhaut Allrad USA

While Iglhaut has kept busy in Europe, and has had special projects around the globe, they haven’t ever had a presence in North America. That all changed after Daniel Kuttner fell in love with a 1990 Mercedes 410 with Iglhaut AWD system.

Kuttner has been fascinated with Mercedes vans for a long time, importing, daily driving, and selling many over the past 20 years. It all started with Mercedes firetrucks, which live their lives indoors, have low miles, and are constantly serviced and driven by professionals.

In order to import them into the U.S. they had to be 25 years old, which is about the time German Fire Departments look to replace a vehicle regardless of miles or condition. Kuttner considers this a “match made in heaven.”

“Being well-versed in the logistical nightmare of importing vehicles, Kuttner figured out how to make the ultimate Iglhaut 4×4 Sprinter a reality for U.S. customers—Iglhaut Allrad USA was born.”

The last firetruck Kuttner owned was a 1990 Mercedes 410, the precursor to the Sprinter. The 410 was up-fitted with an Iglhaut AWD system.

He purchased it in Switzerland with only 7,000 original miles on it. He drove it to the Abenteuer/Allrad Expo, the largest overland gathering in the world. At the show, he approached Iglhaut about opening the U.S. market for their awesome product.

Kuttner thought, if he was to spend top dollar on a Sprinter buildout, why not start with the ultimate platform. He was tired of hearing, “All the cool stuff is in Europe,” at the North America overland shows.

Being German himself and speaking the language opened the door for Kuttner to work out a deal with Michael Iglhaut for exclusive U.S. distribution of Iglhaut products. Of course, the deal was hashed out over some bratwurst and beer.

Being well-versed in the logistical nightmare of importing vehicles, Kuttner figured out how to make the ultimate Iglhaut 4×4 Sprinter a reality for U.S. customers—Iglhaut Allrad USA was born. The first order of business was building his own show truck as a proof of concept.

Read More: 4×4 Sprinter Blazing Trails

The Process

For the U.S. market, the process begins by sending a U.S. specification two-wheel-drive Sprinter to Iglhaut in Germany. It then takes Iglhaut a few months to complete the 4WD conversion.

The process is done completely within their facility in order to ensure top-quality control. Turnaround times, from van purchase to delivery, right now for a U.S. Sprinter 4WD conversions is five to six months.

“Finishing off the Iglhaut upgrades is a rear door spare tire carrier and a centrifugal snorkel, which makes the van sound like a fire-breathing dragon.”

Basic all-wheel-drive Sprinter conversions start at approximately $50,000 and can go all the way up to $95,000. That price includes all logistics, shipping and the conversion itself, but not the base van. That means that a U.S. Iglhaut converted Mercedes Sprinter will cost from about $90,000 to about $145,000.

As a side note, Iglhaut also converts the Mercedes Metris van to permanent all-wheel drive with up to three locking differentials. Ultimate off-road minivan?

Iglhaut is a Worldwide Mercedes Van Partner and therefore their conversions are able to retain the factory Mercedes warranty on the base vehicle. Iglhaut also provides a two-year warranty to private owners and one-year for commercial clients.

Stability and Handling on the Trail

While its towering stance may catch your eye, the Iglhaut-converted Sprinter’s road manners are anything but top-heavy. Unlike what you might expect from a vehicle of this size, the thoughtful engineering behind the conversion ensures that most of the van’s weight sits low—thanks to the robust driveline, suspension upgrades, and those beefy 37-inch BFGoodrich M/T tires hugging the corners.

Out on the trail, what matters isn’t just the van’s height, but its overall footprint. The long wheelbase and wide track give this rig a surprising amount of stability, even under quick maneuvers or hard braking. Whether you’re weaving down a dirt track or testing the limits on pavement, the Sprinter remains composed. Sure, it’s not aspiring to out-handle a sports car, but it’s astoundingly sure-footed for something that doubles as a backcountry home on wheels.

If anything, the biggest concern isn’t body roll—it’s keeping an eye on low-hanging branches along the way!

American Iglhaut 4×4 Sprinter

Kuttner’s U.S. show truck started life as a 2017 Mercedes Sprinter Crew two-wheel drive. Now it has everything Iglhaut offers.

• Permanent 4×4 System with 50/50 power split
• Selectable High/Low Transfer Case (1:2.5 ratio)
• Three Electronic Differential Locks
• Upgraded Brakes, Leaf Springs & Steel Skid Plates
• 37-inch BFGoodrich M/T Tires on 18-inch Alloy Wheels
• Centrifugal Snorkel giving it a throaty, fire-breathing growl

Off-Road Superpowers: Lockers and Low-Range

So, how do locking differentials and low-range gearing actually transform your off-road experience? Let’s break it down—because these are the game-changers that separate a grocery-getter from a legit trail conqueror.

Locking Differentials:
Imagine you’re tiptoeing your way across uneven terrain, one tire biting into soft mud and another hanging midair, waving to the crowd. Normally, a standard differential would send most of the power to the tire with the least grip (not ideal, unless you’re planning an impromptu dirt ballet show). But with a locker engaged, torque gets split equally across the axle—power goes wherever there’s grip. Translation: Even if one tire is off the ground, the other keeps pulling you forward. No wild tire spinning, just steady, predictable progress over ruts, rocks, and those classic “are-we-stuck?” moments.

Low-Range Gearing:
Now, let’s add low-range gearing to the mix. This isn’t about speed—think of it as ‘slow and steady wins the race,’ only the race is against gravity, mud pits, and axle-twisters. Low-range uses a reduced gear ratio that lets your engine churn out maximum torque at low speeds. You crawl, not careen, over trails, giving you immense control when the going gets steep or when precise wheel placement matters. Steep rocky climbs, deep trenches, or those “I wonder if this was a road in the first place” kind of obstacles suddenly become much less intimidating.

The Real-World Effect:
On technical terrain—where wheel lift is a given and weight shuffles like a teeter-totter—these upgrades mean:

• Less drama, no unexpected lurching or wild weight shifts.
• Far more control when a wheel leaves the ground.
• Predictable, composed responses (instead of abrupt spinning and skittering).
• A lot more confidence for the driver, especially when things get sketchy.

In short, locking differentials and low-range gearing are your get-out-of-stuck-free cards, letting you slow things down, stay in command, and keep the adventure moving forward, not sideways.

Tackling Tough Terrain

Curious how this machine deals with the real-world obstacles you’ll find off the beaten path? On the trail, it’s clear that the Iglhaut-converted Sprinter is purpose-built for confidence—think fire-breathing dragon meets mountain goat.

When approaching steep side slopes, the van feels planted, thanks to a suspension tuned for stability rather than drama. Even at substantial angles, there’s no unsettling wobble or sway—just firm footing and no reason to clench your teeth (or your steering wheel).

Cross-axle ravines are where most vans get a bit squirrelly. Not so here. The permanent 4WD system, paired with those electronic lockers, helps you keep crawling forward even as tires lose contact. Hit a deep rut, spin a wheel, and a simple tap of the locker buttons keeps forward progress steady and predictable. It’s all about keeping the van moving slowly, in control, and without surprises—a far cry from the wheel-spinning antics of a stock Sprinter relying solely on traction control.

Breakover angles are no joke in long-wheelbase rigs, but this build takes them in stride. Thanks to beefy side steps and Roambuilt sliders, even breakover humps that test other vans are handled with a reassuring scrape—if anything scrapes at all. No drama, no hang-ups, and no need to pull out the winch.

In short: lock the diffs, pick your line, and watch the Iglhaut Sprinter make easy work of the kind of obstacles that usually separate showpieces from true off-roaders.

Exterior Upgrades

Besides all the quality Iglhaut upgrades, this van also has a full complement of exterior metal from Roambuilt; including,

• Roambuilt’s brand-new Safarirack 2.0 roof rack
• Rear door ladder
• Rear tube step bumper, side steps
• Front winch bumper

The rack is fitted with five Hella 4000 rally lights, while the bumper is fitted with two Hella lights and a Warn Zeon 12-S Platinum winch.

Interior Upgrades

The main use for this remarkable Sprinter is as the showpiece for Iglhaut Allrad USA. This means that Kuttner travels to a wide range of shows all across the country to drum up sales. This has led him to make the van comfortable, both while traveling and around camp.

Inside the driver compartment, you’ll first notice two beautiful Scheel-mann seats.

They are the Vario F models with black checkerboard cloth inserts and black leatherette surrounds, with optional heat and map net pockets.

These make long days on the road exponentially more comfortable than the OEM Sprinter seats.

While the living area in the van is still a work in progress, Kuttner chose Adventure Wagon’s New 2.0 Interior Conversion Kit as the base for the build out.

The system features sound dampening insulation, dual Maxxair fans, Lumicoin LED lighting, bamboo wall and ceiling panels, a wiring loom, and lots of L-track.

The Adventure Wagon interior system uses a powdercoated subframe to which the anodized L-track is attached. The system provides tons of tie-down possibilities and makes sure nothing comes flying off the wall while going down tough trails.

This kit has great sound dampening and insulation and offers tons of overhead storage bag and bed system options.

Eventually, Kuttner plans to completely build out the van with diesel heat, hot water, and a cooktop, for a completely one-fuel system.

A kitchen galley with sink and fridge, an Adventure Wagon auxiliary battery system, an sPOD system, and a Goal Zero power station are also in the works.

Kuttner has even envisioned a Japanese soaking tub and Japanese sliding doors separating the cab from the camper area for the ultimate boondocking van life setup.

Off-Road Performance: How Does It Stack Up?

It’s worth clarifying up front: the Iglhaut Sprinter isn’t meant to line up alongside dedicated rock crawlers for a triple-diamond run at Moab. Between its sheer length and lofty roof, there are physical limitations that no amount of clever engineering can entirely erase. Still, for anyone familiar with stock 4WD Sprinters and even E350 conversions, this Sprinter sets a new bar in a few notable ways.

Where the rubber meets the dirt, those massive mud-terrain tires are unmistakable—offering grip galore but also announcing their presence with a soundtrack of low growls on pavement. On the trail, the upgraded suspension, lockers, and serious underbody protection make tricky terrain far less stressful than one might expect from a van this size. Comparatively, it’s a leap forward in capability and, most importantly, in confidence.

Despite the off-road prowess, this Sprinter keeps much of what makes its factory siblings so easy to live with: forgiving steering, stable braking, and a comfortable ride—albeit a touch firmer, thanks to the tire pressure optimized for a fully loaded adventure, not just the commuter crawl. Long days behind the wheel remain surprisingly low-fatigue, something that can’t always be said for its leaf-sprung competitors.

All said, if you’re looking for a true all-terrain van that won’t shake your fillings loose on the way to camp, the Iglhaut Sprinter strikes an impressive balance between serious trail chops and daily drivability.

Real-World Off-Road Challenges

Of course, heading off the beaten path isn’t all panoramic views and peaceful campsites. If you’re planning to get truly remote—say, venturing onto muddy forest tracks or winding your way through desert washes—your van is bound to face its fair share of obstacles.

The natural world loves to keep things interesting, so you’ll need to be prepared for:

• Unexpected washouts that can transform yesterday’s trail into today’s creek bed
• Stretches of deep mud or powdery sand eager to swallow your tires
• Sudden rock gardens or boulder-strewn ruts ready to test your suspension
• Water crossings during rainy seasons that can rise faster than you think
• Steep, loose climbs where traction is worth its weight in gold

It’s not just about clearing the odd curb—real adventure means confronting terrain that’s constantly shifting, often one challenge at a time. That’s where all those upgrades in suspension, traction, and protection really start to shine.

The Future 

Kuttner’s show van has all the bells and whistles Iglhaut offers, except a 48-gallon aluminum fuel tank option, which replaces the 28-gallon OEM tank.

Kuttner is trying to stay one step ahead and has a second van coming back from conversion in Germany this summer: A 2018 144-inch Cargo Sprinter in light gray with every option available from Iglhaut.

Since Kuttner can only drive one van at a time, one of the two will then be available for sale later this summer. Besides taking individual orders, Kuttner is also dreaming up his next big build.

He’s currently dreaming up plans for a 2019 Sprinter or a Sprinter 4500 Chassis Cab with a BoXmanufaktur Expedition box.

“The star of the show is, of course, the permanent 4×4 system with 50/50 power split and a 1:2.5 ratio selectable high/low transfer case.”

Read More: Outside Van Tests New AWD Sprinter Chassis

“The first Iglhaut Mercedes dealership opened in 1965 in Marktbreit, Germany. The dealership quickly gained a reputation for superior quality and craftsmanship, and a can-do special-projects ethos.”

Iglhaut Allrad Sprinter Specifications

Platform: 2017 Mercedes Sprinter 144-inch Crew Diesel 2WD (USA Model)

Engine: 3.0L V-6 BlueTec Turbodiesel

Iglhaut Allrad System: Permanent 4×4, High/Low Transfer Case (1:2.5 ratio), three electronic differential lockers, leaf spring, and front brake upgrades

Wheels & Tires: 37-inch BFGoodrich M/Ts with 18-inch Alloy Wheels

Accessories: Iglhaut Allrad centrifugal snorkel, skid plates, fender flares, rear door and spare tire carrier; Roambuilt Safarirack 2.0, side step rails, rear tube step, and front winch bumpers; Warn Zeon 12-S Platinum winch, Hella 4000 Rally Lights

Interior: Scheel-man Vario F heated seats, Adventure Wagon 2.0 interior conversion kit with MOAB Elevator bed and MULE Overhead Storage Lockers

Editor’s Note: A version of this article first appeared in the September/October 2019 issue of Tread Magazine.