AL-KO Enduro X Air caravan suspension upgrade: Part 2

We conclude the suspension upgrade on our Trakmaster van and hit the road to Cape York for the ultimate test.

In the first part of our suspension upgrade, we watched the engineers at the AL-KO Service Centre in Campbellfield, Vic, remove the old Sugar Glider trailing arm system from our 2012 Trakmaster Tanami before beginning the installation of an Enduro X Air suspension system (see it in issue 662 and online here). In short, we selected AL-KO’s Enduro X Air because of its lighter components and a softer, safer ride thanks to adjustable airbags, twin shock absorbers and air-over-hydraulic actuated brakes with ventilated rotors. The system also includes AL-KO’s Electronic Stability Control (ESC) as an added feature.

In part one, we explained that the Enduro X system uses replaceable stub axles, which can be set at two heights with a 50mm variation. We chose the lower setting, which provided ample ground clearance, but you could opt for a higher ride if you wanted extra height. We had already added around 40mm of clearance from the suspension and another 40mm by choosing larger-diameter wheels and tyres, which also enhanced the look and gave the van a more modern impression.

Airbags and coils

With the lightweight trailing arms for the independent suspension setup in place, we needed to configure all the necessary ancillaries. Our new Enduro X has an Airbag Man airbag system to replace the old coil springs, with an onboard stainless-steel air tank and a compressor, both mounted midway under the van and protected from flying stones by a steel cross member. I plan to add a rubber shield down the track for extra protection. With the onboard tank in place, high-pressure air lines were connected to the suspension’s airbags using push-on connectors. The air suspension automatically sets the ride height when travelling and allows the van to be levelled side to side when camped. For offroad situations, the ride height can be raised to prevent the van from being soaked during deep water crossings or damaged on rocky tracks. We placed the control panel right at the van’s entry door, where it’s easy to access when setting up camp or preparing to drive.

A lever on each side above the trailing arm suspension mechanically adjusts the system’s automatic ride height by ensuring the bags are set to 195mm high, irrespective of the load in the van. When they are level, a valve stops airflow from the air tank, but if they are unlevel, the system adds or drains air from the bags to restore the correct setting. It’s a great system because when camped the van can be levelled to suit the site and when you’re ready to drive off it’s easy to reset the automatic height from the control panel. The optimum ride height is set up for each combination of trailer and tow vehicle, and once at the correct setting owners can adjust the height by 90mm or retract it by 50mm.

Fitting the air tank and pump

AL-KO Electronic Stability Control

AL-KO’s Electronic Stability Control (ESC) is an excellent safety feature that automatically applies the brakes if its potentiometer detects sideways movement of 3G (gravitational force) or more. Our LandCruiser 200 Series tow vehicle supplies power to the ESC from a new red Anderson plug connection, which must be plugged in before all other electrical connections. The system then self-checks every time the van is hooked up. A light mounted on the A-frame flashes red when the ESC is connected, then settles to a solid green, indicating all is well.

How AL-KO Sway Control works

The AL-KO Sway Control system continuously monitors trailer yaw (side-to-side movement). A proprietary algorithm is used to determine the difference between quick steering to avoid a road obstacle (or other such circumstances) and the rapid onset of a trailer swaying event.

It measures the angle, travel distance and speed of the lateral motion of the trailer (and other parameters) and uses this information to quickly intervene with the application of independent left or right side trailer brakes.

The processing capability of the AL-KO Sway Control is powerful and rapid. It captures all the critical elements of the swaying condition and uses this information to predict how the event will proceed without any driver intervention.

Installing AL-KO ESC

Upgrading to AL-KO iQ7 Outback brakes

A primary reason for upgrading the suspension was the addition of ventilated disc brakes on all four wheels. AL-KO’s iQ7 Outback features a powerful air-over-hydraulic brake setup. The iQ7 is a high-pressure air pump housed in a new metal box welded to the driver’s side of the caravan chassis. This Outback version uses a remote air compressor that we installed in a small space under the fridge, thereby protecting it from dusty conditions. The compressor maintains the air reservoir, which activates the brake fluid as soon as the brakes are applied.

The new air brake system replaces the old breakaway unit. If, for any reason, the van disconnects from the tow vehicle, the brakes automatically engage. This is because the iQ7 Outback incorporates its own breakaway system, eliminating the need for an additional one.

Fitting the AL-KO iQ7 Outback hydraulic brakes

Poly-coated braided brake lines were run along the chassis and trailing arms to keep them safely out of harm’s way. The brakes activate from the usual 12-pin plug, while a separate 12V power supply for the brake compressor connects via the new Anderson plug connectors from the LandCruiser’s battery. Once the team at the AL-KO Service Centre bled the brakes and tested their action we were nearing the completion of the installation, with only a final test drive left before handing over the keys.

Testing the new AL-KO air suspension and hydraulic brakes

The journey from Campbellfield to our home in Merimbula, NSW, offered a mix of city and highway driving to test the new setup. On the freeway through Melbourne, I noticed the van felt smooth and stable, but the biggest impression was that the brakes were much more effective. Their action was smoother and more powerful, and as I covered more miles, I noticed none of the lockup that drum brakes can sometimes cause.

Out on the open dual-carriageway roads east of the city, I also noted that there was no sway from the van when a B-double came past. They used to drag the van towards them, but now the ride felt more stable. It was also smoother over undulating road sections, with much less pitching and a more controlled ride.

Although not a safety issue, the van now looks more modern and capable, thanks in part to the raised body from the larger wheels and tyres, which, from new, were an unusual 235/75R15 size. The much better ventilated discs have addressed any added braking performance required by the larger wheels. Unfortunately, and in a hit to the budget, the larger wheels meant we had to update the compliance plate, which we arranged through Tough Gear Engineering in Canberra, ACT.

Once we finished our home run, we checked the wheel bearings for play, as is required after the first 1000km. They were perfect, but it’s a timely reminder that regular inspections of bearings and wheel nuts are vital.

Heading offroad to Cape York

After a couple of weeks at home, we headed to Cape York in northern Queensland, clocking up a few thousand kilometres since the upgrade — and my admiration for the AL-KO system has only grown. The van tows smoothly and predictably at speed, even on some of the worst sections of the notorious Bruce Highway. Strong side winds have tested the stability, and it has proven its worth. The roads to the Cape can be challenging, with long stretches of corrugations where we lowered our tyre pressures, but the van remained stable over the worst of the roads. We noticed that the interior survived the conditions in much better shape, with loose items staying in place.

Putting the new AL-KO upgrade to the test on a trip to Cape York, Qld

When the lights turned orange in an 80km/h zone through Rockhampton, the stopping power from the brakes caused my wife, Heather, to remark that they were much better than the old system — and she’s right. I also feel much more confident on long, steep descents that we will be able to stop safely if needed.

Setting up camp on sloping ground now takes just 30 seconds by raising or lowering the relevant side of the van to make it perfectly flat — much easier and quicker than driving onto blocks. I also like that I can pump up the van tyres after lowering the pressure on corrugated roads. It’s quick and easy with the supplied hose and fittings while using the air tank.

Final thoughts on the AL-KO upgrade

The transformation is remarkable. Our Trakmaster Tanami now tows more smoothly, handles confidently in all conditions, and sets up at camp in seconds. Add the reassurance of stronger brakes and ESC, and the peace of mind is worth every cent.

The AL-KO Service Centre in Campbellfield can handle all manner of suspension upgrades and maintenance, as we saw when transforming our old Trakmaster. If your van isn’t performing how it should or you want added safety, give them a call.

 AL-KO Service Centre
20–22 Ainslie Road
Campbellfield Vic 3061
P: 03 9997 4700
E: info.aus@alko-tech.com

THE NEXT STEP

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Related articles:

AL-KO Enduro X Air caravan suspension upgrade: Part 1

Caravan suspension explained: What you need to know

Caravan brakes explained: Drum, disc, controllers and safety