Chassis technology for caravans: chassis, axles and braking systems

    Travel safely with your caravan with AL-KO VT chassis technology

    What components make up the caravan chassis?

    The chassis technology on a caravan includes everything that supports, guides and brakes your caravan: the caravan axle, overrun device, wheel brakes and shock absorbers. The AL-KO VT axle uses rubber cords for suspension and is maintenance-free. This page explains the construction and helps you find the right components.

    A caravan chassis consists of a small number of precisely matched components that work together. These elements include:

    • Axle: The rubber suspension axle supports the caravan and provides suspension via rubber cords between the hexagonal outer tube and triangular inner tube.
    • Overrun device: When braking, the caravan pushes against the towing vehicle due to its inertia. The overrun device then applies the caravan's wheel brakes via the transmission device.
    • Wheel brakes: The brake on each wheel is operated via the overrun device and helps bring the vehicle combination safely to a stop.
    • Shock absorbers: These dampen axle oscillation and ensure smooth running.
    • Drawbar and towing connection: These link the axle and coupling to the towing vehicle.

    The chassis: lightweight chassis system and VARIO X

    The chassis is the frame that supports your caravan. AL-KO VT manufactures it as a lightweight chassis system with a galvanised frame that can be adapted to the size and weight of the caravan. It connects the axle, drawbar and body into a stable unit and forms the base for the entire chassis technology.

    VARIO X takes weight optimisation a step further. Its design is inspired by nature: honeycomb-shaped webs near the drawbar and branch-like structures around the axle provide high stability while using less material. Less weight in the frame means more usable payload for your luggage.

    • Weight: With the permissible gross weight unchanged, the lighter chassis can provide additional payload capacity.
    • Payload: The weight saved is available as additional payload.
    • Design: The four frame components use approximately 30 per cent less steel and feature precision laser perforations.
    • Material: Steel remains the load-bearing material and is fully recyclable.

    Lightweight chassis system

    High stability at a low weight. Optimum driving comfort and high level of driving safety.

    VARIO X lightweight chassis

    VARIO X - inspired by nature

    Caravan axle: Euro Delta semi-trailing arm axle and hexagonal rubber suspension

    Caravan technology for high driving stability

    When travelling with a caravan or transporting valuable items, you want everything to arrive undamaged. This is why good chassis suspension is essential. The hexagonal rubber suspension from AL-KO VT provides increased comfort while driving thanks to long suspension travel and smooth suspension. This is due to the independent wheel suspension, where each wheel can move independently. This allows the suspension to absorb road surface irregularities effectively.

    A trip into the mountains with a caravan is a truly special experience. For safe travel, the chassis should remain stable when cornering and effectively reduce sway, helping to maintain consistent contact with the road. For safety on winding routes, the AL-KO VT Euro Delta semi-trailing arm axle helps provide stable handling through adjustments to the toe-in. This enables stable driving behaviour during overtaking, in crosswinds, including on bridges, and when cornering. During such manoeuvres, the load is mainly on the wheel on the outside of the bend. With AL-KO VT caravan technology, the semi-trailing arm axle redirects the forces acting on the wheel to the axle stub. Toe-in and negative camber increase, causing the wheel to counteract centrifugal force and helping the vehicle remain stable in curves.

    Euro Delta semi-trailing arm axle

    The AL‑KO Delta semi-trailing arm axle acts counter to centrifugal force.

    Hexagonal rubber suspension

    Relaxed driving with low material wear

    Enduro X chassis for off-road applications

    The new off-road single-axle chassis solution and centre section

    Maximum performance off-road. Discover the Enduro X: an off-road solution that sets new standards for anyone travelling away from paved roads. Whether on rough terrain, in professional applications or for demanding leisure use: Enduro X impresses with its genuine off-road capability and individually adjustable toe and camber settings.

    AL-KO Enduro X – The new off-road single-axle chassis solution & centre section

    Maximum all-terrain performance with the AL-KO Enduro X solution for off-road use

    Maintenance and care

    The rubber suspension axle on your caravan is maintenance-free. It provides suspension using rubber cords between the hexagonal outer tube and triangular inner tube, uses no steel springs and has no grease points requiring regular attention.

    However, the brake requires attention: have the wheel brakes and overrun device checked and adjusted at least once a year or before the start of the holiday season to maintain a short braking distance and ensure your vehicle combination comes to a safe stop.

    You should also keep an eye on the shock absorbers, because worn dampers can allow the axle to oscillate too much. These tasks can be handled by an AL-KO VT service centre that is familiar with your chassis and uses suitable original parts.

    Frequently asked questions about caravan chassis technology

    The chassis consists of the axle, the overrun device at the drawbar, the wheel brakes and the shock absorbers. The axle supports the weight and provides suspension, while the overrun device operates the wheel brakes. Together, they ensure safe and smooth driving.

    The rubber suspension axle requires no maintenance, as it has no grease points and uses no steel springs. However, the wheel brakes should be checked and adjusted regularly—ideally once a year or before the start of the season. An AL-KO VT service centre can do this for you.

    Depending on the model, VARIO X saves around 25 to 30 kg compared to a conventional frame. This weight is available to you as additional payload. The key is a design inspired by nature that uses around 30 per cent less steel in the frame.

    The permissible axle load is shown on the axle type plate and in the vehicle documents. AL-KO VT axles are available for loads from 750 to 3,500 kg per axle. This value must not be exceeded, even with your payload.

    Whether a payload increase is possible must be checked for each caravan individually. Depending on the chassis, axle, brake system, tyres and wheels, a payload increase based on documentation alone may be sufficient, or technical modifications may be required. The caravan manufacturer must approve the higher permissible gross weight. After any necessary modifications, an authorised inspection body will check the vehicle; the changed data is then entered in the vehicle documents by the registration office.