Perhaps not quite in a formal way, but would this be a 'diy' option of upgrading a 1000KG rating on my current Troll axle to a 1200KG loading? Currently, I'm pushing my max weight before we add any clothes etc...

That's encouraging, Colin. The 'body tested to 1200kg' - would that still be the case for a 2002 (MY) 540..Are all Troll bodies rated to a max of 1200kg? Presumably a lower rated axle (ie 1000kg) would have been a cheaper option at the time?

Edit to add: I have sent the message to Hymer regarding the replacement plate

Yes - that's my next move and I'm arranging to visit the van (in storage) to get a photo of the plate. In the meantime, I have spoken to Western Towing who initially had some doubts as to whether this could be done but have asked for the plate image, then they will take it up with Alko. As to costs, it was suggested about £600 for the axle and they could fit for around £100.. Since then, I've had another thought. Will I need to replace the wheels? I have it in my mind that a 1200Kg axle requires a 4 stud wheel. Although the attached photo isn't necessarily helpful, I think they are 3 stud...

DSC_0005.JPG - Bild entfernt (keine Rechte)

Actually, I think I have 4 stud wheels and the 1200 axle requires 5. In hindsight, that makes more sense...?

Our messages are crossing. Are we agreeing that I would need 5 stud wheels?

Thanks, Colin...

I'm quite excited to report that I have heard back from Hymer confirming that my Troll can be upgraded to the 1200kg axle. They have supplied details of the relevant chassis drawings (both as delivered at 1000kg and upgraded at 1200kg) and a list of a number of steps I have to take. I'm clarifying a couple of those points with them at the moment. They will charge me €200 for the provision of the new plate. I am going to discuss this with Western Towing (though with them based in Exeter and me in Cambridge that is not the easiest of arrangements) and will keep you up to date of progress as things pan out.

I have checked back and that last time I was weighed before departure on holiday, the van came in at 1100kg (it has electrics, an awning, spare wheel etc, etc), so I have been pushing my luck. It makes a lot of sense to me to get this done, somewhat regardless of cost

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The note from Hymer ony mentioned tyres though there might also be some 'rim' information in here as well - I have yet to check:

Please also enquire about the tyres that will be required after the load has been increased.

According to our information the tyres 195/70 R 14C 91 T on 6 J 14 H2 should be valid. Please have this checked again by AL-KO.

Though I am assuming wheels will also be required as I guess the hubs on the new axle wil be the 5 stud rather than 4. That requires a little more research and I'd be happy to hear from anyone that already has any suggestions. Equally, a perfectly serviceable 1000kg axle and appropriate wheels will be available after this has been completed...

More to come on this, I expect...

Edit to add: Something like this then...

Werbung: https://www.ebay.co.uk/itm/ALLOY-WHEEL-V...7-/143309575937

Hmmm - hold that..

This may not be as straight forward as first thought. I have spoken to Western Towing now having forwarded on the Hymer email. What my contact there is suggesting is because of the change in dimensions of the heavier axle (suspension drop arm length etc) it may well be that new chassis rails would also be required. The axle fits into a cut out in the chassis rails and if the new axle were to be fitted to the current chassis, then the wheel centres would come further back and hence, the wheels would not fit in the wheel arch.. He is going to source the chassis diagrams from Alko as Hymer have suggested to check..

Bu%%er.. So may not be possible then (without a ridiculous amount of work) Hopefully I will know for certain in the next few days. Big up to Western Towing though. He was thinking about my enquiry whilst eating his dinner last night and worked this all out beofre I had even heard from Hymer..

We remain hopeful..