Air suspension problems

[smrkolj.sebastjan@gmail.com]

Hello experts,
I’m planning a big trip around Australia next year and getting my D3 ready. It currently has 234k km on the clock.
Question: based on current km, can I expect air suspension parts to start failing on me soon? What is the first thing I should start looking as potential problem? Any signs of wear I can look for?
So far everything is working fine.
Oh, and I’ll be towing 2.5t van ;)

Thanks,
Seb

[BrianElloy]

I know what I’d be doing before a “lap” with that many Kms on the clock plus towing a van

- airbags
- shocks
- compressor
- wheel bearings
- gearbox, engine and transaxle lubes
- cooling system and AC service
- maybe LCA’s

Seriously that’s a lot to ask an old girl to cope with, without doing some serious preventative maintenance

[PerthDisco]

Just buy an ex Wicked bongo wagon as they seem to be capable of endless laps of Australia requiring nothing but fuel top ups.

I’d bet the Disco would do it fine still but at least get those components closely checked if you don’t know the history of them well.

Additionally;
Coolant flush
New water pump
Replace plastic coolant fittings

[smrkolj.sebastjan@gmail.com]

I know what I’d be doing before a “lap” with that many Kms on the clock plus towing a van

- airbags
- shocks
- compressor
- wheel bearings
- gearbox, engine and transaxle lubes
- cooling system and AC service
- maybe LCA’s

Seriously that’s a lot to ask an old girl to cope with, without doing some serious preventative maintenance

Thanks Brian,
Grearbox and rear diff getting reconditioned later in the yaer. Front already done.
Cooling system definitely something to inspect.
Is there a way to determine how close compressor and air bags are from failing?

[Grappler]

Thanks Brian,
Grearbox and rear diff getting reconditioned later in the yaer. Front already done.
Cooling system definitely something to inspect.
Is there a way to determine how close compressor and air bags are from failing?

If there are no suspension faults being logged, the EAS compressor is probably OK. You should however, change the dessicant in the compressor drier and upgrade the the drier cap. You can test the bags and EAS system by removing the EAS fuses and checking for sag overnight. I believe leaving a door ajar also defeats the EAS valves. If it sags look for air leaks with a spray bottle with soapy water.
The suspension lower control arms (LCA) bushes and/or swivel joints, usually become cluncky at about 200K, so I would check as they may have already been done

[smrkolj.sebastjan@gmail.com]

If there are no suspension faults being logged, the EAS compressor is probably OK. You should however, change the dessicant in the compressor drier and upgrade the the drier cap. You can test the bags and EAS system by removing the EAS fuses and checking for sag overnight. I believe leaving a door ajar also defeats the EAS valves. If it sags look for air leaks with a spray bottle with soapy water.
The suspension lower control arms (LCA) bushes and/or swivel joints, usually become cluncky at about 200K, so I would check as they may have already been done

Thanks, much appreciated. Will check for any leaks like you mentioned.
LCAs were checked and so far nothing loose yet, but I think they will have to go on the list nonetheless

[101RRS]

You can really go overboard on preparation and replace everything (of course many do nothing).

For the suspension I would get the compressor rebuilt before you go - probably $120-$150. Buy an o ring kit to rebuild the valve blocks if they were to play up. Airbags do not have a history of failure even at high km so a failure would be the exception - visual inspection is probably OK.

I would invest in a EAS emergency inflation kit - GOE used to do them but it would seem they no longer make them so research how it is done and build one.

As far as the suspension is concerned I dont see any other prep is needed.

Garry

[SeanC]

Thanks Brian,
Grearbox and rear diff getting reconditioned later in the yaer. Front already done.
Cooling system definitely something to inspect.
Is there a way to determine how close compressor and air bags are from failing?

Is the trip mainly on the highways or will there be some remote off-roading as well? If you are going places were you can’t get help from RACQ etc, then that’s another level of preparation.

If you are going remote, critical components should be changed by age not by waiting for the first signs of failure. What age? If you are asking for signs of failure then it’s probably time to replace. I know it’s tempting to get as much use from a component that you can, especially if it’s an expensive component but it’s not worth getting stuck in the middle of nowhere.

How old is the compressor? It might seem fine when you leave home but it’s a big trip. If it’s the original, replace it you have definitely got you money’s worth. If its’s not the original but has done say 150,000kms I would think about replacing it and keep it as a spare.That’s what I did.

Airbags rarely fail catastrophically but the shock absorbers get soft usually giving a wallowing feeling. New airbags will definitely help with towing. If these are the originals then it might be time to replace.

Alternator maybe if it is the original.

The upper water housing under the throttle body.

Airbags, compressor and alternator, water housing are quite easily done at home. If I can do it than anyone can. Source the parts from the UK and install yourself and you will save a lot.

The more hands-on I get with the vehicle the more confidence I have in the vehicle and in my my ability to resolve potential problems when off-road. DIY is not just about saving money.

Enjoy your trip.

[smrkolj.sebastjan@gmail.com]

Awesome. Thanks for your feedback guys!
Air compressor on the to do list as well ;)
Alternator replaced last month.

Our trip will be mainly coastline with finding as many beautiful beaches as possible ;) There will definitely be corrugated roads and sand driving, don’t envision much if any proper off road tracks.

[SeanC]

Awesome. Thanks for your feedback guys!
Air compressor on the to do list as well ;)
Alternator replaced last month.

Our trip will be mainly coastline with finding as many beautiful beaches as possible ;) There will definitely be corrugated roads and sand driving, don’t envision much if any proper off road tracks.

Looks like you have it pretty much sorted.

[Oztourer]

I know they are expensive but a Disco specific diagnostic tool like a Nonocom or similar is invaluable. Combined with Dr Google, this will help greatly in anything you might encounter on your travels. I had a simple EAS fault (faulty ride height sensor) that resulted in me getting an $$$ ride on a flatbed from Gundagai back to Sydney. If I knew then what I know now about my D3, I could have got myself out of trouble. I have the GEO kit sitting in my shed that I still need to fit. It’s made up of standard industrial pneumatic fittings.