The 1994 Mercedes 250GD is more than just a vintage 4×4—it’s a legend in the off-road world. Built for rugged military use, this G-Class Wolf model has become a sought-after base for enthusiasts looking to create something extraordinary.
Turning a 250GD into a high-performance custom G Wagon requires more than a paint job and new wheels. It takes mechanical expertise, a deep respect for the vehicle’s heritage, and a vision for blending modern performance with timeless design.
Here’s how to reimagine this classic into the ultimate custom-built G.
Why the 1994 Mercedes 250GD is a Perfect Starting Point
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Originally designed for military deployment, the 1994 250GD was part of the revered “Wolf” series—G Wagons built for extreme reliability and utilitarian use.
Powered by a naturally aspirated diesel engine (OM602) and paired with a rugged 5-speed manual transmission, the 250GD is known for its durability, simplicity, and off-road capability.
Its boxy frame, solid axles, and body-on-frame construction make it an excellent candidate for a full custom rebuild.
Unlike modern SUVs, the 250GD’s mechanical design allows restorers to upgrade and modify almost every component without compromising the vehicle’s structural integrity.
Planning the Build: Define Purpose and Performance Goals
Before turning a wrench, it’s important to plan the build with intent. Ask yourself:
Will this G Wagon be a weekend off-roader? A daily city cruiser? A collector’s piece?
Each purpose demands a different approach. For instance, a trail-focused G might need aggressive tires, a snorkel, and reinforced underbody armor.
A daily driver could benefit more from sound insulation, refined interior comfort, and updated safety features.
Clarity at this stage helps set the tone for what to preserve, what to enhance, and what to completely transform.
Powertrain and Performance Upgrades
The stock 250GD engine is known for reliability—but not speed. For those craving more horsepower and torque, an engine swap is a common solution.
Many custom shops replace the OM602 with the turbocharged OM606, offering smoother acceleration and better highway performance.
Transmission upgrades often follow. A modern 6-speed or automatic transmission paired with the new engine provides better drivability and fuel efficiency.
Suspension improvements are essential, too. Swapping the factory setup for heavy-duty shocks or adjustable coilovers increases ride comfort and handling, both on and off the pavement.
Brake upgrades—such as front disc conversions—enhance safety and stopping power.
These enhancements preserve the G Wagon’s legacy while preparing it for the demands of today’s roads.
Body and Interior Customization
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One of the most exciting parts of any custom build is transforming the look and feel of the vehicle.
Externally, restorers may opt for military-inspired paint, powder-coated bumpers, LED lighting kits, or steel fender flares. Some even add a safari-style roof rack or rear ladder for adventure-ready functionality.
Inside, the transformation is dramatic. Builders often strip the interior completely, applying heat and sound insulation before installing custom leather seats, modern dashboards, and infotainment systems. Even the flooring can be upgraded with marine-grade vinyl or hardwood inserts for added luxury and durability.
For those looking to start their own transformation, Expedition Motor Company offers a purpose-built platform to help you build your dream custom G Wagon from a vintage military Wolf. Their process focuses on mechanical restoration, tailored styling, and performance upgrades designed to meet your lifestyle.
Electrical and Technology Enhancements
The 1994 250GD was built for the field—not for luxury or tech. So a proper custom build includes an overhaul of the electrical system.
This typically involves replacing or rewiring the original harness, installing a modern fuse panel, and integrating tech upgrades such as USB ports, LED cabin lighting, and high-output alternators.
Many builders also incorporate modern safety and convenience features. These include backup cameras, keyless entry, GPS navigation, digital gauges, and Bluetooth audio systems. These updates make the classic G feel current without sacrificing its vintage charm.
Detailing and Personalization
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The final stage is where the build truly becomes personal. Every decision—from paint color to stitching on the seats—adds to the vehicle’s identity.
Popular choices include matte military finishes, deep gloss blacks, or custom hues that blend old-school style with contemporary flair. Wheels and tires also play a big role, with many opting for beadlock-style wheels or classic steelies wrapped in all-terrain rubber.
Custom badges, cargo area upgrades, soft-top conversions, and dash plaques round out the details. These small touches leave a big impression—especially for owners who want to stand out at shows or on the trails.
Final Thoughts: A Legacy Reimagined
Transforming a 1994 Mercedes 250GD into a custom G Wagon is more than just a project—it’s a passion. It’s about taking a purpose-built military machine and shaping it into something deeply personal and road-ready.
Whether you’re restoring for performance, style, or nostalgia, a well-executed build ensures the G’s story continues for decades to come.
With expert craftsmanship, thoughtful upgrades, and a clear vision, the result is not just a vehicle—but a legacy redefined.
