For the first time, ZF Aftermarket has introduced its own range of air springs in renowned Sachs quality. With repairs to air suspensions posing new challenges for automotive workshops, with this new range the ZF product experts have made air spring replacement as easy as possible for workshops. In addition to model-specific service information, there will soon also be special training courses on the subject of air suspension.

In the past, air suspension was an exclusive feature for the luxury class - today, however, it can be found in more and more mid-range vehicles and SUVs. There are already six million cars on the road in Europe that have air springs at least on the rear axle, but in many cases they are on both axles. An important advantage of this type of construction is that level control is always available, which is why it is often used on the rear axle of estate cars, SUVs or vans with high payloads. In addition, this design ensures greater driving comfort and is lighter than a conventional steel spring.

To ensure that automotive workshops can also rely on high-quality ZF products in this growing market segment, ZF Aftermarket has introduced its own range of air springs under the Sachs brand. Sachs air springs are made of high-quality, corrosion-resistant material, have a long service life and high resistance to external influences. In addition, they are easy to remove and install thanks to their customized and precise geometry and the special air connection.

Markus Wittig, Head of the Business Line Passenger Car Aftermarket, says: "We are supplementing our unrivalled range of high-quality parts and leading services with an innovation from the chassis sector, which is strategically important for us. With Sachs air springs, we not only supply our workshop customers with a product of exceptional quality, but also offer optimum support during replacement on the vehicle: on the one hand through the particularly good installation properties of the product, but also through model-specific service information that can be easily accessed via smartphone."

The new product from Sachs is now available for vehicles with separately arranged springs and dampers. This includes many models from Audi, BMW and Mercedes-Benz, but also from Citroën, for example. The portfolio will grow steadily in the coming months.
Step by step: replacing an air spring

The most common reason for needing to change the spring is air loss. This can be recognized when the vehicle drops significantly during longer standing times or does not reach its driving level at all. If the driver ignores this damage or does not even notice it, the compressor goes into continuous operation because it has to compensate for the pressure loss. This leads to increased wear on the compressor and possible premature failure.

The use of a diagnostic device is indispensable when working on the air suspension. This applies not only to troubleshooting, but also because some vehicles require it to be put into a service or lift mode. Other car manufacturers prescribe removing the compressor fuse when working on the air suspension. It is essential that workshops consult such model-specific manufacturer instructions before starting work. This is where customers of ZF Aftermarket have an advantage, as the spare parts specialist provides all the necessary technical information for air spring replacement. Service information can be quickly accessed via smartphone. A QR code in the product packaging leads to a ZF website with the appropriate repair information for the respective model.

Before removal, the mechatronics technician must drain the air spring. In most cases, he can issue the command to do this via the diagnostic device. This process can take several minutes and its completion is indicated by the diagnostic device. When the spring is empty, the mechatronics technician can remove it. Since stand-alone air springs are usually only clipped in, this is very quick and easy - unlike steel springs, which require a spring compressor.

Fitting the new part is just as easy. When fitting the air hose, an innovative product feature of the new ZF air springs makes installation easier. The spare parts are already equipped with a pre-assembled air connection into which the hose only has to be inserted. With products from other suppliers, on the other hand, the air connection must first be pre-assembled during assembly.

At the end of the repair process, the mechatronics technician initiates the refilling of the air spring using a diagnostic device. Of course, for a balanced repair, air springs should always be replaced in pairs, just like steel springs or dampers.