Specs, fluids & service · 1992–2022
Mercedes-Benz G-Class W461 specs, fluids and service intervals
The numbers you need in the garage, on one page: spec sheet, capacities and service intervals, wheels and tires, and the parts to order. Sourced from owners, specialists and the factory; tags marked confirm in manual haven't been checked against a factory source yet.
Spec sheet
| CHASSIS | W461 |
|---|---|
| YEARS | 1992–2022 (civilian to 2019) |
| BUILT IN | Graz, Austria |
| BODY | W460-based, narrow |
| DRIVE | Full-time 4WD, dual range |
| LOCKERS | Centre, rear, front |
| ELECTRICS | 24 V (military) |
| CRAWL RATIO | 41.0:1 (G 300 CDI) |
| TIRES | 265/75R16 (G 300 CDI Pro) |
| CLEARANCE | 245 mm (cab-chassis) |
| APPROACH / DEP. | 38° / 35° |
| SUCCEEDED BY | W464 (2022) |
By year
| YEARS | PLATFORM | ENGINE | OUTPUT | NOTES |
|---|---|---|---|---|
| 1990–1991 | 250 GD 'Wolf' | OM602 2.5 L I5 diesel | 92 PS | Bundeswehr spec. Wikipedia lists it under the W461 |
| 1992–2001 | 230 GE / G 230 | M102 2.3 L I4 | 125 PS | Petrol working G |
| 1992–1997 | 290 GD | OM602 2.9 L I5 diesel | 95 PS | Naturally aspirated; 0–100 km/h in 25–27 s |
| 1998–2001 | 290 GD Turbodiesel | OM602 2.9 L I5 turbodiesel | 120 PS | Direct injection; automatic only |
| 2001–2006 | G 270 CDI | OM612 2.7 L I5 turbodiesel | 156 PS | Common rail. Canada's LUVW used a 2.7 five-cylinder |
| 2007–2014 | G 280 CDI | OM642 3.0 L V6 turbodiesel | 184 PS | Military 'Worker', plus the 2009 EDITION.30 PUR and Professional |
| 2010–2019 (civilian) | G 300 CDI Professional | OM642 3.0 L V6 turbodiesel | 135 kW / 400 Nm | Wagon, van, cabrio and cab-chassis; military trucks built to 2022 |
Fluids, capacities & service intervals
Ex-fleet and ex-military W461s are often maintained by the book but stored for years, so refresh every fluid and rubber part. Military trucks run 24 V, and glow plugs, bulbs and blower motors must match the system. Specs vary by engine, from the 290 GD to the OM642 CDIs, so confirm capacities and fluid approvals for your VIN.
| ITEM | SPEC / CAPACITY | INTERVAL | NOTES & PARTS |
|---|---|---|---|
| Engine oil & filter | Oil approval per manual for your engine confirm in manual | At purchase, then per manual | 290 GD and 300 GD-era trucks share filters with their W460/W463 relatives. CDIs use cartridge filters.Oil filter — 300 GD / 240 GD · Expedition Imports ↗Oil filter — 230 GE · Expedition Imports ↗ |
| Glow plugs (diesel) | 24 V plugs on 24 V trucks | At purchase if starting is slow | Fitting 12 V parts to a 24 V truck, or the reverse, kills them quickly.Glow plug 24 V 000 159 82 01 · Expedition Imports ↗ |
| Air filter | OE element; check the dirty-filter warning | At purchase; often in dust | The Australian G 300 CDI Professional has a dirty-air-filter warning (WhichCar).Air filter — 300 GD / 350 GDT (W463 range) · Expedition Imports ↗ |
| Fuel filter & water separator | OE-type | At purchase | Military trucks may have sat with old diesel. Drain the water separator.Fuel filter with water separator 002 477 10 01 · Expedition Imports ↗Inline diesel pre-filter · Expedition Imports ↗ |
| Coolant | Mercedes-approved coolant confirm in manual | At purchase | Pressure-test the system and check the radiator and hoses.Radiator cap 461 501 00 15 · Expedition Imports ↗Thermostat 87 °C · Expedition Imports ↗ |
| Automatic transmission fluid & filter | Per manual confirm in manual | At purchase | The 1998–2001 290 GD Turbodiesel and later trucks are automatic-only.Transmission pan magnet · Expedition Imports ↗ |
| Transfer case | Per manual confirm in manual | At purchase | Full-time dual-range case. Check that the centre lock engages and releases. |
| Front & rear differentials | Hypoid gear oil per manual confirm in manual | At purchase; after water crossings | Three lockers: test each one after the change.Differential drain/fill plug · Expedition Imports ↗ |
| Locker hydraulics | Flush and bleed | At purchase | Handsome Motors advises flushing the hydraulic system first when a lock won't actuate.Front brake / rear locker hose · Expedition Imports ↗ |
| Brake fluid | DOT 4 confirm in manual | At purchase, then every 2 years | Bleeder cap · Expedition Imports ↗ |
| Front axle: kingpins, swivels, bearings | Inspect and grease | At purchase | Kits differ by axle and year, so check the axle number.Kingpin bearing kit · Expedition Imports ↗Steering ball wipe seal · Expedition Imports ↗ |
| Batteries & charging | 24 V system (military) or 12 V | At purchase | Load-test both batteries and replace them as a pair. Check the 24 V alternator output on military trucks.24 V 55 A alternator 006 154 39 02 · Expedition Imports ↗ |
| Cardan shaft recall (2016–21 G 280/300 CDI) | Dealer recall check | At purchase | Recall for trucks built 4 April 2016 to 13 September 2021 (Autocar). |
Capability
| Towing | 2,210 kg (4,872 lb) G 300 CDI Professional cab-chassis, 4X4 Australia |
|---|---|
| Payload | about 2,080 kg (4,586 lb) cab-chassis, 4,490 kg GVM; 6,700 kg GCM |
| Fuel tank | 96–97 L (25.4–25.6 US gal) WhichCar (wagon) / 4X4 Australia (cab-chassis) |
| Ground clearance | 245 mm (9.6 in) cab-chassis |
| Approach / departure / breakover | 38° / 35° / 22° cab-chassis |
| Crawl ratio | 41.0:1 |
| Curb weight | 2,410 kg (5,313 lb) cab-chassis |
| Engine | 135 kW / 400 N·m OM642 3.0 V6 turbodiesel, G 300 CDI Professional |
Wheels & tires
| Factory tire | 215/80R16 or 255/75R15 (1993 230 GE / 290 GD listings) · 265/75R16 (G 300 CDI Professional) |
|---|---|
| Bolt pattern | 5x130 |
| Center bore | 84.1 mm |
| Lug thread | M14x1.5 |
| Biggest tire · Stock | 235/85R16 (≈32 in) |
Common G-Class W461 repairs
- Cardan shaft recall checkDIFFICULTY 1 / 5
- Front axle service (bearings, kingpins, swivel seals)DIFFICULTY 4 / 5
- Locker won't engageDIFFICULTY 3 / 5
- Springs and shocksDIFFICULTY 3 / 5
- Steering box resealDIFFICULTY 3 / 5
- No heat or fan (24-volt blower)DIFFICULTY 2 / 5
- Sagging doors and hinge rustDIFFICULTY 2 / 5
- Windscreen gasket, wiper spindle and floor leaksDIFFICULTY 3 / 5
Always confirm torque figures, fluids and capacities against the factory service manual for your VIN. See the disclaimer; some parts links are affiliate links.