Mudguards

Mudguards protect the wheel areas against splashing water, mud, stone chips and spray from the wheels. For MAN and Mercedes trucks, buses and vans, they protect not only other road users, but also brake components, air springs, wiring harnesses, sensors and chassis wiring. A correctly fitted mudguard limits contamination of brake discs, brake calipers and EBS (Electronic Braking System) sensors. For vehicles used in distribution, construction or international transport, intact wheel protection is essential for safety, legal compliance and reliable operation.

Mudguards vary considerably depending on axle configuration, tyre size, wheelbase, cab version and application. Separate front axle mudguards are available for MAN F90, F2000, TGL, TGM, TGA, TGS, TGX and TG3. MAN TGE vans and Lion’s City, Lion’s Coach and Neoplan buses also use vehicle-specific wheel protection. For Mercedes, this includes versions for Atego, Axor, Actros, Arocs, Econic, Sprinter, Vito, Citaro and Tourismo.

Depending on the version, these may include fixed cab mudguards, plastic wheel arch liners, mudguard shells above front axles, parts with integrated mudflap brackets or separate mudguard extensions. Plastic versions are often made from impact-resistant PP (polypropylene), PE (polyethylene) or glass fibre-reinforced composite. Metal versions are generally galvanised steel or aluminium. The shape, radius and clearance around the tyre must match exactly: insufficient tyre clearance can result in rubbing at full suspension compression, steering lock or when snow chains are used.

Parts must always be identified using the vehicle chassis number. Visual comparison or selection based solely on the model name is never sufficient, as identical vehicle series may have different mudguard widths, mounting points and axle loads.

The most common damage is caused by contact with site materials, tyres or obstacles during manoeuvring. Typical fault patterns include hairline cracks around mounting lugs, torn mounting holes, deformed mudguard brackets, missing clips, loose wheel arch liners and worn mudflap brackets. On plastic parts, UV ageing and low temperatures can make the material brittle. Steel brackets and mounting rails corrode especially where the coating has been damaged by stone chips.

First check for visible cracks, sharp edges and contact marks on the tyre sidewall. Then measure the clearance between the tyre and mudguard on both sides with the wheels straight ahead and at maximum steering lock. On air-suspended trucks and buses, also check at fully raised and lowered ride height. Assess the brackets for torsion and measure the distance to the tread at several points; a deviation often indicates a bent support rather than just a damaged mudguard. Also inspect wiring harnesses, ABS (Anti-lock Braking System) sensor cables, air lines and brake components for stone-chip damage or abrasion contact.

Replace a mudguard when cracks extend from mounting points, when the material is permanently deformed or when wheel coverage is no longer sufficient. Repairing a small plastic area is only advisable if the structural mounting zones, material rigidity and original contour are retained. A welded or filled crack around a mounting point will usually tear again due to vibrations.

Always fit new mudguards with suitable brackets, reinforcement plates, clips and corrosion-resistant fastening materials. Use the specified tightening torques: excessive preload deforms plastic mounting lugs, while insufficient clamping force causes loosening. Replace damaged rubber spacer bushes to prevent stress cracks and resonance. Correct fitment and, where applicable, supply in the vehicle colour help minimise repair time and vehicle downtime.