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#13 Lightswitch conections.

#12 Connecting the odometer / speedometer.

#11 Why Does the Odometer Cable Keep Breaking?

Many customers order a new odometer cable because the old one is broken. However, quite often we receive reports shortly after that the new cable also breaks immediately after installation.What is going on here?
The Cause: Seized Magnetic Coil
A common reason is that the vehicle has been stationary for a long time. This causes the lubrication in the odometer to dry out, resulting in the magnetic coil seizing. The gearbox drives the cable, but if the odometer side does ...

#10: Why Do the Inner CV Joint Bolts Break So Often?

A common and frustrating issue with the Iltis is the loosening of the inner CV joints, especially on the short drive shafts. Once the CV joint comes loose, it starts to “click” back and forth — quickly leading to broken bolts.
The cause is surprisingly simple.
1. The Main Reason: Two Different Bolt Lengths Starting in 1979, VW used two different bolt lengths for the CV joints: - 45 mm → for short drive shafts - 50 mm → for long drive shafts
This worked fine ori...

#9: The Difference Between Bombardier and VW Iltis Drive Shafts

The difference between Bombardier and VW Iltis driveshafts:
When Bombardier began producing the Iltis for the Belgian military in 1985, the Ministry of Defence requested the integration of a front differential lock (see also Blogpost #5). To handle the added mechanical stress, Bombardier proactively reinforced the short drive shafts on all four wheels.
What exactly is different about the Bombardier drive shafts? It’s important to note: only the CV joint and the spline of the stub...

#8: Why Do the Warning Lights on the Speedometer Stay On?

A common question from Iltis owners: “Why do the warning lights on the speedometer stay on or keep glowing, even when everything seems fine?” Fortunately, the cause is usually simple — and so is the fix.
The Cause: A Design Flaw in the Alternator Mount One known weak point in the Iltis is the rubber insulator at the top of the alternator mount. Originally made of soft rubber, this part gets compressed during installation. Over time, the alternator can come into contact with the...

#7: Suspension donuts engine and differentials.

Blogpost #7: Suspension donuts engine and differentials.
1) Introduction. Both the VW and Bombardier iltis use a total of 14 of these suspension donuts. With these, the entire drivetrain is mounted in the chassis. That is why we have chosen to produce them in-house, so we can guarantee top quality. VAG: 183199381A - 183 199 381A NSN: 5340121737964 Iltisshop: A0452
2) When should I replace the suspension donuts? The condition of these donuts can best be evaluated when they are ...

#6 - Help, my iltis is leaking oil.

Blogpost #6: Help, my iltis is leaking oil.
1) Which seal set to choose? We often get the question "which seal do I need?". That's why we have created a handy overview, in which you can immediately see which set to choose.
2) How to order: You can easily search by article name in our webshop, see →

3) Refill differentials with oil. Gearbox: 3.6L - 80W90 Rear differential: 1.6L - 80W90
Article number iltisshop oil: A0522

#5 - Differential locks

Blog post #5: Differential locks.
1) goal: A major disadvantage of the Iltis is the limited suspension travel. That is why the vehicle is equipped with a rear differential lock, and later also with a front one. We see that customers are often not familiar with the use and/or operation of the differential lock(s) that are included as standard with the Iltis.

2) What is an open (standard / non-locked) differential? To understand what a locking differential is, we first need t...

#4 - Installing brake adjusting gears.

Blog post #4: Installing brake leveling gears.
VAG Numbers: -Bolt: 183 609 221 - 183609221 -Rondel: 183609227 -Wolf roundel: N0122314 -Friction washer: 183 609 229 - 183609229 -Adjusting gear: 183 609 225 - 183609225 Iltisshop reference for the complete set: Set21
1. goal: A total of 8 of these sets are used in the car. This allows the brake shoes to be adjusted. Sometimes the teeth are worn out, or the entire set no longer clamps properly on the anchor plate. These sets ar...

#3 - Ignition switch removal.

Blog post #3: disassembling the ignition switch.
1) Theory. To prevent the ignition lock of the Iltis from being simply replaced, these were permanently attached to the housing at VW. Once the lock is pushed into the housing, a spring steel latch springs into a recess. Order number iltisshop ignition lock: A0185
2) disassemble. However, it is quite simple to disassemble these locks. For this it is necessary to drill a hole directly above the spring steel lock with a drill of 3 mm....

#2 – Batteries.

Blog post #2: Batteries.
1) Which battery to choose? We are often asked which batteries are suitable for the VW & Bombardier iltis. The (military) Iltis uses a 24V system and therefore has 2x 12V batteries in series.
The batteries of the Iltis are located under the rear seat, and are therefore limited in height. Never use batteries higher than 190mm (ideally = 175 / 180mm). This prevents the poles from making contact with the bodywork during assembly & disassembly.

#1 - Replacing the shock absorber rubber.

Blogpost #1: Replacing the shock absorber rubber.
VAG shock absorber: 183413029Iltisshop reference shock absorber: A0333
VAG rubber loose: 183413381AIltisshop reference rubber loose: A0254
If you do not have special tools, it is necessary to carry out this installation with 2 people.

1) Dismantling the old rubber: It is best to carry out these works with the lower eye of the shock absorber clamped in a vice.
To remove the old rubber, insert 2 sturdy flat screw...