The retrofit

GCK MOBILITY

Technological innovation to decarbonize heavy vehicles and give them a second life

Since April 4, 2020, it has been permitted to convert a combustion engine vehicle to a cleaner technology in order to reduce its greenhouse gas and pollutant emissions. This practice, known as retrofitting, involves removing the combustion engine and fuel tank from the vehicle and replacing them with a 100% electric solution, such as a hydrogen fuel cell or a hydrogen combustion engine.

Vehicle retrofit

The original engine block and its ancillary components (tanks, gearbox, catalytic converters) are removed and replaced with a more efficient powertrain, in compliance with specific regulations. The technical and administrative provisions governing retrofitting were published in April 2020 in the Official Journal.

GCK Mobility adapts retrofit solutions for all types of heavy-duty vehicles, drawing on the technological expertise offered by all the subsidiaries of the GCK group.

There are three technological options:

Electric retrofit with battery energy storage: replacement of the combustion engine with an electric motor with battery energy storage. A simple solution with minimal maintenance costs.
Electric retrofit with hybrid battery-hydrogen energy storage: replacement of the combustion engine with an electric motor with hybrid electric-hydrogen energy storage. The best range/power/refueling time ratio for heavy and special vehicles.
Retrofit with hydrogen combustion engine: conversion or replacement of the engine with a hydrogen combustion engine. A promising technology still in the experimental stage and suitable for intensive use/operation in demanding environments.

As the manufacturer of the first French bus retrofitted with hydrogen in series production, GCK Mobility is positioning itself as a pioneer and innovator in the field.

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The advantages of retrofit

Zero CO2 emissions

Fast fleet transformation

Contributing to the circular economy

More economical than a new vehicle

Converting a vehicle brings several concrete and immediate ecological and economic benefits:

Polluting, sometimes outdated mechanical parts are replaced by a zero CO2 emission solution;
Conversion allows components that would otherwise have been manufactured for the assembly of a new vehicle (bodywork, interior elements, running gear, etc.) to be retained;
A retrofitted vehicle highlights the environmental commitment of a company or urban area in its efforts to create a hydrogen ecosystem.

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Regulations

Regulations concerning retrofitting provide a framework for all stakeholders in the field. The government decree of March 13, 2020 sets out specific rules and imposes essential conditions for a project to be valid.

Which vehicles are eligible?

The vehicle registered in France must be structurally sound (bodywork without corrosion, wiring harnesses in good condition, etc.) and meet the safety requirements for roadworthiness:

The vehicle undergoing the conversion must be more than 5 years old;
The conversion must be approved for each model;
Once the retrofit has been carried out, the vehicle may have a maximum power output of between 65% and 100% of the original power output;
The weight distribution between the different axles may not be changed by more than 10%;
The total weight after conversion must be within +/- 20% of the original weight.

The legal framework surrounding retrofitting differs depending on the type of vehicle concerned. Thus, the approval process is not the same for light vehicles, heavy goods vehicles, or special vehicles used off-road (off-road retrofit).

France is a pioneer in retrofit issues and already has a set of binding certification rules in place. National regulations are part of a European framework, a cohesive system that makes it easier to obtain this essential authorization in other EU countries.

A retrofit can be supplemented by:

A refit, i.e., the repair of worn or damaged components;
A restomod, an operation that consists of modernizing the vehicle in order to give it a visual appearance and level of comfort in line with current standards for new models. In the case of a coach, for example, we can update the lighting and the driver’s cab (dashboard, seats, mirrors).

Homologation

The legal framework for retrofit differs depending on the type of vehicle concerned. No approval procedure is required on the part of the purchaser of a retrofitted vehicle. It is the conversion kits themselves that have been approved in advance. The experts at GCK Mobility carry out this process in their capacity as developers and manufacturers.

A certification process lasting several months

GCK Mobility works in collaboration with several specialist manufacturers (Iveco, Renault) and its sister companies (GCK Battery, GCK EMI, GCK Performance, Solution F) to develop kits for a wide range of models.

The approval of the various technological components (fuel cells, batteries, and electric motors) is a prerequisite. These components are examined independently, one at a time.
The vehicle itself is then approved. The initial document is retained, and only the components that have changed are subject to new procedures.
It is important to note that each type of vehicle must be approved.

A retrofitted vehicle is covered by a warranty on all components of its powertrain (all new parts are covered). All retrofitted vehicles also receive a conversion plate indicating the name of the kit manufacturer, the vehicle’s VIN number, the prototype approval number, and the reason for conversion to electric power.

A world first

In February 2024, GCK Mobility made history by obtaining a road approval certificate for a retrofitted hydrogen-powered coach. Following the validation of all UTAC and CNRV approval tests, the IVECO Crossway coach is now authorized to drive on public roads.

This is a world first, enabling the launch of mass production of coaches retrofitted with hydrogen fuel cells.

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