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Thread: Replacing air suspension struts - who's done it?

  1. #1
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    Replacing air suspension struts - who's done it?

    I plan to do a Kimberly trip next year towing a camper trailer with the D3. In researching this I was a bit chastened by the experience of Greg Milner, who had a catastrophic failure of an air-suspension shock on the Gibb River road.

    My D3 has 145k on the clock. Given that quite a number of the members here have a whole lot more, , I am wondering what the experience is with suspension strut replacement.

    Questions of interest include:

    -How many k's had your vehicle done when you needed the suspension replaced
    -what were the symptoms that indicated that replacement was necessary?
    - is it more cost effective to replace the whole unit, or just to re-insert a new shock?

    And the big one.... How should one judge if they should be replaced or not before tackling a big Kimberly trip?

  2. #2
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    Did mine at 120000 or so. Shocks were stuffed long before that point. Changed entire strut - bag and shocks - as that seemed simplest and best bang for buck.

    If you've done 145000 and it's still on the originals you'll notice a massive difference in ride and handling as your shocks are likely to be pretty well shot. It is a slippery slope however, once you start doing suspension things you may notice other bits that could do with a refresh and down the rabbit hole you go ... good luck !

  3. #3
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    Epic pooh,
    My RRS has done similar km's.. it seems to be all ok and probably had a softer life, but you've got me thinking it's not going to be too far down the track.
    What did the replacement cost?
    Rob.
    SIII FFR 2.6; STAGE 1 3.9; RRS 4.4;
    REMLR member 114

  4. #4
    Join Date
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    Quote Originally Posted by Epic pooh View Post
    ...It is a slippery slope however, once you start doing suspension things you may notice other bits that could do with a refresh and down the rabbit hole you go ... good luck !
    But at that point we are all chasing the rabbit flat out, so keep upgrading until we catch it...
    Regards, Will

    Stornoway Grey '09 D3 TDV6 SE, 2015 TERRITORY Engine at 348k
    LLAMS, FYRLYTS, OL D4 Bar
    Safari Snorkel, D4 hitch, ARB CKMA12

  5. #5
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    Strut replacement (aka the thin end of the wedge) was around $1400 or so (from memory - 2 years ago ex-uk using allmakes pr gear which is Dunlop branded not Delphi (oem) or genuine).

    Gave me back my magic carpet ride and restored good handling but then set me on a quest to return suspension to "as new" ... Just about to start on the rear and then I will have changed out pretty much every suspension bush and steering component and lots more to boot. Madness I know ... But ... I like my disco so it can be rationalised as cheaper than a new car and better the devil you know and like !

    Also V8

  6. #6
    Join Date
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    I had one removed and refitted chasing a rattle, d2dave removed my drivers side strut, 2hrs all up I reckon, we spent most of the time looking for a socket that fell into the engine bay the hardest part was refitting the air line.

    Baz.
    Cheers Baz.

    2011 Discovery 4 SE 2.7L
    1990 Perentie FFR EX Aust Army
    1967 Series IIa 109 (Farm Truck)
    2007 BMW R1200GS
    1979 BMW R80/7
    1983 BMW R100TIC Ex ACT Police
    1994 Yamaha XT225 Serow

  7. #7
    Join Date
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    Thanks again Epic,

    Would like to know if mine is worn since I dont have a comparison.
    But I better start my 'RRS repair' fund then - seems it will rival my son's college fund because I also like to replace anything thats not looking or behaving like new!

    Although I do recall you referring to the wear on the drivers seat wedge as 'character' or something along those lines.. is that because it's too hard to replace / repair? - easier to just live with... sorry a bit off topic.

    Rob.
    SIII FFR 2.6; STAGE 1 3.9; RRS 4.4;
    REMLR member 114

  8. #8
    Join Date
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    My country usage shocks get a harder life than city vehicles but I only got 70K out of a set of genuine D3 shocks. The Britpart-sourced Delphis after 40K are barely satisfactory with the vehicle empty but with any weight at all in the back the front floats so I'm starting to consider what to fit next. Maybe I'll return to genuine D4s even though I didn't like their stiffness without a load in the vehicle because of other suspension related ride softening changes made since. Just fitting the spare to the RWC permanently might soften the ride enough anyway.

    With 145K on the airsprings I would urge they be changed at the same time and if not fitting genuine, the extra cost over just the shocks is minimal.
    MY21.5 L405 D350 Vogue SE with 19s. Produce LLAMS for LR/RR, Jeep GC/Dodge Ram
    VK2HFG and APRS W1 digi, RTK base station using LoRa

  9. #9
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    Rob I am pretty sure you can get the entire leather seat cover from LR or aftermarket ex-uk. My attitude is that it is leather and it will age gracefully if properly maintained.

    I'd fix it if it had holes or actual damage but it doesn't so I just do a regular clean and then an application of dubbin keeps it happy and healthy.

    Leather will always get some level of creases as it ages (especially thick leather) = "character" !

    And yes ... The repair find can be quite confronting ... I try not to think about it too much haha

  10. #10
    Join Date
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    When I picked up my D3 it had 192K on the clock. The drive from Cooloongatta to Sydney revealed that the shocks were very floaty. I had already decided to replace the dampers with Bilsteins so it went in as soon as it could and had them fitted.
    While they had the struts out it was evident that the airbags required replacement as they had cracks at the top where the damper rods passed through and would soon fail. So I had all the airbags replaced as well.
    10K later and the front Bilsteins had lost their oil and were replaced under warranty, another 10K and the replacements had also lost their oil. I purchased some Koni FSDs to replace them with however I heard of problems with them as well and decided to go with OEM Delphi struts.
    The Bilsteins were great when new and felt much better controlled than the replacement Delphis. They just didn't last on the front.
    The Bilstein rear dampers continued to work without an issue and I sold the car with 260K.

    My D4 has 112K and still feels nice and tight. I have the set of KONI FSDs sitting in the shed that I will throw on when the originals get a bit loose and we will see how long they last. I expect to replace the airbags at or just before 200K
    Fuji white RRS L494 AB Gone
    2023 Ford Ranga

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