Hymer B544 Front Spring Replacement

Hymer B544 Front Spring Replacement

After clipping curbs across Europe, bottoming out and hitting the stops and even cutting the engine out on a couple of occasions, we figured it was time to sort out Zagan’s low front end. We thought it would be easy to buy Hymer B544 front spring replacements, but it turned out to be a bit trickier and took us almost a month to arrange.

After a lot of reading up on Facebook motorhome forums, it soon became clear that a low front end is a common problem with motorhomes. It seems that the front suspension springs fitted in most of them are just normal van springs, designed to take the weight of a van – a couple of seats, a bit of stuff in the back and maybe the odd Ginsters pastie. For the past 16 years our front springs have had the weight of a drop down bed, two leisure batteries, two captain’s chairs, not to mention all the stuff crammed in cupboards and under the benches behind the cab. It really is no wonder they were getting tired.

We first realised there was a problem when we parked up in a supermarket car park and the bumper hit the curb and cracked. Our heavy duty Milenco levelling ramps were only a centimetre or two lower than the bumper, so on soft ground they would lift up as we rolled off them and inflict more damage to the bumper – so they were left in Croatia when we bought a second-hand pair of lower lightweight ramps from a chap on a campsite. On bumpy roads the passenger side would bang as we bottomed out on the stops, making us cringe.

When we were back in the UK in 2016 we took Zagan for his MOT and mentioned the problems to our garage. They discovered that the passenger side shock absorber had sprung a leak and had no oil left in it, so before the MOT they swapped them both. Sadly it didn’t solve the low front end problem, but surely it should stop us banging on the stops on bumpy roads? Unfortunately not. As we drove through Spain on our way to Morocco, the sickening bang was back, and even more so in Morocco with its bumpier roads and Zagan loaded to the max with life’s ‘essentials’.

The day we were leaving Morocco we hit a huge pot hole in some roadworks and Zagan died on us. He simply wouldn’t start. Thankfully some very helpful cannabis farmers (I kid you not) and the Hymer Owners Group Facebook Forum got us back on the road, and we even made our ferry (which of course was running late). It cut out again another time on a level crossing in France, so once back in the UK it was time to do some research into how to stop it happening.

The simple answer is to replace the front springs. This can be done by several companies, so I got in touch with Travelworld Motorhomes as I had seen many people recommending them. They were very quick and efficient and gave me two quotes, £829 for fitted or £499 for just the springs. After getting back up off the floor, I did a bit more digging around on the internet. I discovered that Travelworld only fit Goldschmitt – the ‘Ferrari’ of springs, which would be great on a fairly new expensive van, but on Zagan it seems a bit excessive.

I spoke to Zagan’s favourite garage (fellow motorhomer Norman) and we talked about what options there were. They could replace the springs with like for like ones for me, but I had heard that you could get a heavy duty version which would be better for a motorhome, so we agreed that I would source the springs and they would fit them.

More internet research introduced me to Lesjofors Springs, who also had great reviews but were a tad cheaper at around £70 each. As they have loads of different types of springs I needed to find out which were the right ones for Zagan. This is where I got stuck in a loop. Based on my VIN number, the online spring retailers told me I needed to use Lesjofors part number 4026148, however their site said this was for a FIAT DUCATO Box (244) (Year of Construction 04.2002 – 07.2006, 122 PS, Diesel), this set alarm bells ringing.

Zagan was registered in 2001 and even if the chassis has been sitting around for a while there was no way he could have been a 2002 base vehicle. After quite a bit of online research I discovered that the base vehicle type is listed in the VIN number and Zagan’s said his base was a 230 (built from 1994 to 2002). So why were they telling me to buy ones for a newer base? More pleas for help from the Hymer Owners Group Facebook forum gave me part numbers of springs that were fitted to a B644 – but I wasn’t sure if they would be the same.

Eventually Norman came to my rescue and was able to give me the original Fiat part number for the springs – however as the base had since had an ALKO chassis fitted and a Hymer built on top of it, he wasn’t sure if this was still the right part. I contacted a couple of motorhome dealers and one of them gave me the same Fiat part number for my springs – a breakthrough, something finally matched.

This Fiat part number was for the 244 base (Lesjofors part number 4026148) which still seemed odd, but as two sources had confirmed it was the same number, I was getting a bit more confident. Next I got in touch with Lesjofors who it turned out don’t deal direct with the public, however they were able to confirm to me that they do produce a heavy duty version of the spring number I had, the Lesjofors 4026169 (or Kilen part number 12152 – they are the same company). 

Hymer B544 Front Spring Replacement

After almost a month of going around in circles it was now or never, so I ordered the heavy duty version – even though the online retailers said it wasn’t compatible with my vehicle. I paid a bit extra by ordering them from Amazon as I know they have a great returns policy (I just walk round to my local post office and send stuff back). When they arrived, they were huge and about 12kg each.

The springs and Zagan were dropped off at the garage and we waited with our breath held. Norman called us a few hours later – they fitted! A huge sigh of relief was let out, our spring saga was over.

So, did they make a difference to the front end? They sure did. We’ve gone up by around 6cm. The pictures below measure from the bottom of the number plate, but in reality the front of the bumper has been lifted from 20cm off the ground to 26cm. This may not sound much but it will stop us hitting curbs and Zagan now looks a lot more level when sitting on a flat car park. Hopefully we’ll have to use our chocks less now.

To get this extra height cost us £140.68 for the springs plus £190 for the fitting (which also included the fitting of a new starter battery as we had to get a jump start to get to the garage!). We have yet to venture on bumpy ground in Zagan since the new springs were fitted, but we are hoping the ride will be better too and we’ll no longer activate the emergency engine cut off!

Ju x

28 replies
    • Scotty says:

      I ordered the heavy duty Lesjofors 4026169 springs same as you did but for my 1998 fiat ducato Hymer E650 and they fit.
      So I recommend if you have a FIAT chassis between 1996 and 2002 then get your garage to order a set of those heavy ones along with a set of whatever their system says should be standard springs for your camper. Then you will be able to compare back to back that they are the same overall dimensions etc just a heavier wire spring. Then your friendly garage will be able to return the ones you don’t want to their supplier at no cost when the supplier next visits (or both sets in the unlikely event that something doesn’t match)

      As further confirmation of the original post -that B544 2001 Zagan uses the same spring as my E650 1998 and that the front suspension is common 1996 to 2002 – If i do a search for springs using my Rego number or VIN plate number then the parts websites (like Europarts) suggest standard spring Lesjofors part number 4026148 (same that was suggested for Zagan) or a KYB RA1777 (it actually says on the website that RA1777 is equivalent to a Lesjofors part number 4026148). So if you search your van rego and get the same result then the heavy duty Lesjofors 4026169 springs should fit.

      If you are still struggling then you could use Grayston rubber spring assisters. You need to jack up the front end and measure the gap between the coils to choose the right size assister. Anyone that is a Maypole dealer will be able to get you some. You aren’t supposed to fit them on the front but even Grayston know acknowledge that people do (i.e. its ”not recommended” but I wouldn’t worry)

      Thanks so much for the original post. I was really struggling. Had written to Fit and to Hymer and loads of spring manufactures and motorhome specialists with no joy. So you’ve really helped me out. Top marks :)

      Reply
  1. Wayne says:

    Gotta tackle these things head-on, get it sorted and forget it, hopefully. Sounds like you got a reasonable deal in the end. Advice for Zagan…chin-up😁

    Reply
  2. Christopher Mackie says:

    Hi, good job. Can you tell me about this emergency engine cut off please. I have a 2003 x244 B544 and never knew there was one.
    Mines always been a little low at the front but never I hit anything, guess what, I`ll be out with the tape measure tomorrow to see how mine compares !
    Someone did tell me that at the age of van, the suspension legs should be replaced as well, did you consider this ?
    Looking forward to your next trip, have you a destination in mind ?

    Reply
    • Jason says:

      Hi Christopher. We had both struts replaced last year as we thought they might have been the issue, turns out they weren’t!
      We were told about the engine cut off by the great gang on the Hymer Owners Facebook group. It’s a small switch either under the glove box or inside the engine, if the van thinks you have been in an accident it cuts off the fuel to the engine as a safety feature. Worth a look to see if you have one, as you never know when a level crossing might activate it!
      Cheers Julie

      Reply
  3. Dave Green says:

    Hi both,
    Good to have a new blog. We have a 1999 B544 Hymer, a little like your Dave, in October we had all the front suspension renewed, I could feel every bump and ridge in the road surface and the headlights shone so low it was impossible to see at night. Although we have only done two short trips in Homer so far, but certainly notice the difference and it’s certainly easier to get level when parked up.
    Looking forward to your next adventures.

    Merry Christmas Dave

    Reply
  4. Philip says:

    Hello Guys,
    I think I’m in the same situation you were in, I have a 2001 B524 Alko chassis base 230, I’m going to get the Kilen 12152 springs, but my question is! did you get your struts also based on a 244 base?. Any help would be great, thanks. Philip

    Reply
    • Jason says:

      Hi Philip
      We had already had the struts replaced the previous mot as one of them had failed. The garage sorted those out for us, so I don’t know what sort went in. They would have sorted the springs for us, but we wanted heavy duty ones.
      Cheers Julie

      Reply
  5. paddy says:

    hi Jason i am going to change my springs on my hymer B584 which i think is based on the same chassis wold u know how manny coils is on the new springs towards the old wne’s as tear’s only 6 coils on my old ones and 18mm in thickness

    Reply
  6. Mervyn Pickard says:

    Hi Jason,
    After approximately 3 months on your new springs, have you noticed much in the way of improved handling and comfort?
    Regards
    Mervyn

    Reply
    • Mervyn Pickard says:

      I am asking as I have a 2001 B694 on the same chassis as Zagan. Just lately the front seems very low and on flat ground the front needs lifting to make the van level. Approx half a tyre width at the top is hidden by the front wing. Is this similar to your experiences pre spring change?

      Reply
      • Jason says:

        Hi Mervyn

        Yes – that’s the same kind of experience we had. Zagan’s front was low enough to catch on high kerbs and on levelling ramps if we used them on grass (they’d kick up a tiny bit as we dropped off them, and caught the bumper as they did). Zagan wasn’t level inside when parked on a level surface. Since having the springs changed, he is almost level inside, and the front has lifted by around 6cm.

        In terms of ride, we haven’t driven him enough to notice any difference. That said, we both drive so conservatively, we don’t tend to notice the suspension a great deal. Our old Hymer had air-assisted suspension (those rubber bag things) on the rear and we couldn’t tell whether it was inflated or not. Same for this new van – one of the front struts emptied itself of oil some time into a year-long trip, and neither of noticed any change in handling. So maybe we’re not very good judges of suspension!

        The biggest improvement for us has been the way the van has been lifted from obstacles at the front, and the fact it’s easier to get level when parking up.

        Cheers, good luck, Jay

        Reply
  7. Debbie mann says:

    Please can someone help ..my rapdio 927f .is listing to one side ..the garage have quoted 1500 me..as they say they have to move the dash board to put new springs on….is ghis correct ?
    There are thousands of a class fiat Ducati out there ..

    Reply
  8. Dave says:

    Hi,
    Very interested in your info re the uprated springs. I have a 1999 x230 ducato and want to do this mod. I spoke to Kilen and they confirmed as you state that they do not do one for the x230 but do for the x244/245 = code 12512. I checked spring dimensions against standard ducato ones and they are 10mm shorter which shouldnt be a problem but diameter is 6mm bigger due to the 21mm spring thickness rather than 18mm on the standard ones so all seams ok as long as the larger diameter sits on the spring plates snuggly. My main question is when you had your shock absorbers changed were they based on x230 spec as if so I think I can proceed with some confidence all will fit. BTW how are they performing 2 years on?……I am cringing over every pot-hole I hit !!!
    Regards Dave (daddy_bangbang) on insta!

    Reply
    • Jason says:

      Hi Dave.
      We had the shock absorbers replaced a year before we did the springs. Our garage sourced the shocks, so I don’t know what they used, but I would assume they would have been like for like. When it came to getting the springs, I was unsure if I had the right ones or if they would fit, that’s why I paid a bit extra and bought them from Amazon so I knew it would be easy to return them if they were wrong.
      Two years on and we haven’t bottomed out or cut the engine out on some bad roads, so they seem to be working well.
      Cheers Julie

      Reply
        • John says:

          Dave (and Julie & Jay of course)
          My research on this revealed 2 x strut shock absorbers that are for Ducato 244 derived vans (like my 2002 B754) – A standard one KYB 635806 with a 25mm top end and a Heavy Duty one KYB 635807 with a 28mm top end. I got hold of a new pair of the HD ones to fit with Kilen 12152 springs but found, when I got my old ones off (the original OEM ones I presume) , that they were the HD ones already and in OK condition so returned the new ones and got my money back.
          BTW I spoke to Norman who told me he’d fitted KYB 635807 HC ones on Zagan in 2016 :-)
          Cheers, John

          Reply
  9. Tommy says:

    Thanks for this helpful post. I have just done both front struts, including new struts, bump stops, top plates and bearings and new top mounts with Kilen 12152 springs for a total cost of £387 fitted. I got an extra 6cm of height at the front. Still a bit low but much better than before. My motorhome is a Hymer B595 2004 model.
    Cheers Tommy

    Reply
      • Tommy says:

        I had them fitted on my driveway Colin. I stripped the dash out myself (very easy just make sure you remove all the fixings). Then I got a mobile mechanic who had a spring compressor to give me a hand as it is a 2 man job. He worked in the wheel arches and I removed the interior bolts. There are 3 top bolts and 4 bottom bolts and that is it. It took us about 3 hours at £35 per hour, hope that helps.

        Reply
  10. Mike saul says:

    Thanks so much for the reply. It has helped a great deal. Like you I have been going around in circles for the last few years. Should have done this years ago. I spent so much time on the road alone I forget there are others out there wiyth the same problems.

    Reply
  11. David says:

    Hi Thanks for the very helpful post. I have the same problem with my 2007 B544 it’s sitting very low on the front and looks like a dragster. I got a quote for VB front springs and or suspension and at £1500 is not really practical. I’m now looking at the Kilen route since reading your post, however there are 2 spring options for our year, a heavy duty and an extra heavy duty and wondered which you went for. The weight on the front axle is 1750kg fully loaded fuel,water and us. Thanks.

    Reply
    • Jason says:

      Hi David

      We don’t recall there being an extra-heavy-duty option when we got our replacement springs, sorry we’ve no idea which would be the best choice for your motorhome.

      Best of luck with it, sorry we can’t me more useful, Jason

      Reply

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