G-Wagen Trail Recovery: Broken Axle, Bent Track Bar & Maxtrax Winching Strategy
July 28, 2025
When a client’s early 90s G350 Turbo Diesel failed miles from home, Alliance Auto Care stepped in. From engine diagnostics to a full OM606 upgrade, turbo improvements, and suspension enhancements, this G-Wagen was rescued and built for long-term reliability.
What do you do when you pick up your G-Wagen and it fails just miles down the road? That’s exactly what happened to this early 90s Mercedes-Benz G350 Turbo Diesel. The previous shop couldn’t solve the problem, so the owner called Alliance Auto Care. Within hours, the truck was transported safely to our shop, and the full diagnostic revealed a seized camshaft — a catastrophic failure that rendered the motor inoperable.
Instead of simply repairing the broken 603 turbocharged motor, we worked with the client to upgrade to a low-mileage OM606. The upgrade included a 6-millimeter mechanical fuel pump and an enhanced turbocharger, balancing increased reliability and drivability without going for extreme power.
The process also involved suspension and chassis updates, ensuring the G350 could stop, steer, and handle perfectly, even with the enhanced engine performance.
The OM606 crate motor arrived from Canada, complete with accessories such as alternator, water pump, power steering pump, AC compressor, and glow plug relay controller. Every component was inspected, resealed, and tested for optimal performance.
The combination of upgraded turbo internals and a carefully spec’d fuel pump ensures smooth operation, minimal smoke, and daily-drivable reliability — perfect for owners who want dependable performance without compromising comfort.
To match the engine upgrade, the truck received Fox 2.0 shocks, factory ride-height springs, and new bushings on control arms and tie rods. This ensures that the G350’s enhanced horsepower translates into precise steering, braking, and handling on the road.
Selecting the correct shop is critical when working on classic or rare G-Wagens. Key considerations:
Experience with Mercedes-Benz, especially early diesels like the 603 and 606.
Familiarity with four-wheel-drive systems; experience with early Land Rovers often helps.
Knowledge of German brands including Porsche, Audi, VW, BMW, for electronics and hard-to-source parts.
Ability to fabricate or source obsolete components like oil lines or wiring harnesses.
If in doubt, our team collaborates with other shops across the country to ensure your G-Wagen gets correct parts and upgrades.
Once your vehicle arrives, we handle:
Transportation logistics nationwide.
Full top-to-bottom inspection.
Clear communication of all options — repair, upgrade, or enhancement.
Execution of engine rebuild or upgrade, turbo tuning, suspension improvements, and chassis work.
This G350 project highlights the importance of strategic upgrades over quick fixes. By focusing on reliability, drivability, and proper engineering, we ensure this classic diesel G-Wagen can perform for many years to come.
Expect a 4–8 week timeline, depending on parts availability and scope. A full job like this can range from $10,000 for partial work to $30,000+ for full disassembly, rust remediation, paint, and reassembly. But in Joe’s words: “The money you put into it now pays dividends down the road.”
Interested in restoring your G-Wagen?
Contact Joe Gocher at Alliance Auto Care in Loveland, Colorado.
Get in touch with Joe Gocher and the team at Alliance Auto Care—we’ll get your truck squared away the right way.