It’s important to make sure you’ve got the right vehicle setup when you head offroad, particularly if you’ve also got a van in tow. Suspension plays a key role in this, so we spoke to the experts on how you can ensure your vehicle and trailer are up to the task.
When it comes to Aussie-made suspension, Tough Dog 4WD Suspension is the self-proclaimed leader of the pack. We’re certainly fans, with our chief (John Ford) running a GVM upgrade in his personal LandCruiser 200 Series and plenty of first-hand experience with Tough Dog upgraded rigs.
Tough Dog has been producing its innovative suspension setups since 1985 and has a combined experience of more than 100 years, with all Tough Dog products researched and developed at the company headquarters in western Sydney.
They are by no means an unfamiliar name in these pages, having been a major sponsor at our Caravan of the Year competition for two years now, and joining us as the naming sponsor of our inaugural Australia’s Best Hybrids event last year, when they did something new and exciting and launched their first suspension system built for caravans and camper trailers.
But where Tough Dog has really etched a place in the market is with its 4WD suspension gear and upgrades.
The right suspension setup is essential for any driving, whether you’re sticking to on-road touring or heading offroad, with or without the van in tow. But if you are planning a trip offroad, it is important to take stock of your setup and determine whether or not a suspension upgrade is advisable or required.
So, to shed some light on how you can improve your suspension setup, we spoke to Blake Jones, Tough Dog’s marketing and commercial manager.
Consider your setup
It’s not just leaving sealed roads that can put more strain on your 4WD or tow vehicle (and van) setup. While corrugations, uneven and rough terrain will increase your suspension’s workload, the weight of your vehicle and van plays a big role in how the suspension performs. The heavier your setup is, the harder your suspension has to work when driving on rough and undulating tracks. And if your setup doesn’t suit the conditions, your ride quality and control will suffer.
You need to understand your weights, including any additions you’ve made, to determine if your suspension setup is suitable
So, it’s essential to know how much your vehicle weighs and the tow ball weight of your van, taking into account any additions you’ve made to the setup and how these can affect where weight is distributed. For example, a bullbar and winch adding heavy loads to the front of your vehicle and/or fridge drawers and water tanks adding weight over the rear of the vehicle — or any other gear you’d add to your setup before an extended trip off the beaten track.
Blake explained that while OEM suspension systems are designed for your vehicle, they do have limitations. These systems aren’t necessarily designed to carry any additional weights, which can increase the wear, tear and degradation of your vehicle's suspension. This is why it’s important to check that your suspension is suitable for your setup so that it can control the movement and weight of the vehicle. “When offroad the surfaces aren’t as flat and the undulation and weight of the car puts more stress on the suspension, which is controlling the movement of the car,” Blake said.
“When factory suspension carries extra weight, it compresses the suspension, which lowers the ride height and intensifies the pressure on the suspension components. This situation can lead to the shock absorbers approaching their maximum compression length more frequently, rather than performing effectively within their designed range.
“A variety of suspension upgrade options are available, allowing us to tailor the solution to meet the specific needs of the customer, taking into account the vehicle’s weight and intended use. We evaluate all relevant factors to determine the most suitable suspension upgrade, whether it involves complete suspension kits or simply the installation of rear airbags,” Blake said.
A before and after of a Tough Dog front suspension upgrade
Suspension upgrades for on-road touring setups
Offroad driving isn’t everyone’s cup of tea — or is something only undertaken once in a blue moon. But even if you prefer to stick to the road more travelled, a suspension upgrade can benefit your vehicle and towing experience.
“A suspension upgrade is not just for offroading by any means,” Blake said. “As soon as you add accessories to your vehicle, your factory suspension is not designed to carry it. On-road or offroad, setting up your vehicle to suit your weights is imperative. Whether you’re touring from caravan park to caravan park or going offroad, setting up your vehicle suspension is the way to go. Factory suspension is designed to suit everyone, but not one shoe fits all. Getting a suspension upgrade that is tailored to your needs and requirements rather than a one-size-fits-all from a car manufacturer is always going to improve your driving and towing experience.”
Suspension upgrade underway at one of Tough Dog’s dealers
Tough Dog leaf spring upgrade
How suspension failures start to show
When we asked Blake what can happen to a suspension system overtime and how failures start to show, he said the bushes in shock absorbers are the first thing to go. “It’s the part that wears and perishes the most. It has a certain amount of force put on it. The bushes are made of rubber and are designed to have a certain amount of flex. Over time, and with more movement [such as offroad driving] means it is going to wear out and degrade.” There’s no set lifespan on a shock bush, it just comes down to driving style, weight load, road conditions and the environment and how these impact the rubber. So, it’s somewhat inevitable that offroad driving and towing, particularly in Australia’s hotter or coastal climes, will cause them to degrade faster.
Luckily, shock bushes are a fairly easy and cheap part to replace when required. But they should be checked regularly with services as a preventative measure, as driving on degraded bushes can lead to steering control issues, stress on the vehicle joints and shaking/shimmy up front. Any mechanic will be able to do the job, and shock bushes are readily available from suspension manufacturers. They are specific to each vehicle’s shock absorber, so if you’re heading into remote corners of Australia, it’s probably worth checking if you should replace them before you go or bringing a couple of spares in your 4WD toolkit to avoid any unnecessary delays.
When it comes to the rest of the suspension setup Blake said you should get many years before any failures start to show. The caveat is how regularly the vehicle is used and how well it is looked after, but Blake explained that there’s no need for concern as long as the shock absorber is still maintaining control of the vehicle and operating as it should. “If you start hearing knocking or feel the car undulating or moving more than usual, it’s something to look at,” Blake advised. Preventative measures are key here, and suspension setup and performance should be inspected during your regular routine services.
Tough Dog offers a range of suspension options to suit your 4WD’s setup
What a suspension upgrade offers
There are plenty of benefits to getting a suspension upgrade, many of which come in handy when heading offroad. The improved comfort, ride quality and handling are some of the standouts, especially when it comes to tackling heavily corrugated routes like the Gibb River Road or the road to Cape York.
Choosing the right upgraded suspension kit from Tough Dog is crucial for aligning the correct spring rate with the vehicle’s usage and weights. It is highly recommended to invest in a complete kit rather than selecting individual components. Tough Dog’s suspension kits are specifically designed to pair the correct springs with the appropriate shock absorber with optimal valving, ensuring they function effectively together. Upgrading only the springs while retaining the factory shocks can result in a mismatch, as the factory shocks are not built to accommodate the increased ride height of the vehicle, leading to potential damage and failure of the factory shock absorber.
Getting a suspension upgrade can improve your ride quality
It’s important to have the correct springs for your setup
A suspension upgrade will also (generally) give your vehicle a lift due to the new and improved taller springs, thereby increasing your ground clearance. This gets a gold star from offroad fans and can open up more out of the way destinations that would have been unwise to attempt with a factory setup.
New versus old springs
Tough Dog has 400 stockists Australia-wide and dealers in every state and territory (and overseas as well). When looking into a suspension upgrade and what this would look like for your 4WD setup, Blake recommends heading to your local dealer to discuss not only your vehicle but also any accessories or weights that have been added, and if you’re planning any future upgrades and when they will take place. If you’re planning on towing as well, you don’t need to bring the van but it’s important to have your weights handy, particularly the down ball / tow ball weight of the van because this will designate the weight/pressure the van will place on your vehicle.
Suspension upgrades are unique to every vehicle and owner, determined by the overall weight, intended use and requirements of the vehicle.
“When going in to discuss your suspension upgrade, let them know what you’ve got on your vehicle and van, how much the van or trailer you’re going to be towing weighs when fully laden and the down ball weight so that the Tough Dog team can work out what best suits your setup and travel requirements,” Blake advised.
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Toyota HiLux before and after getting an upgrade
Suspension versus GVM upgrade
Before you go down the suspension upgrade route, Blake recommends figuring out if you need a gross vehicle mass (GVM) upgrade instead, which Tough Dog also offers.
It’s a complex subject, but Blake explained that the best way to determine whether you need a GVM or a suspension upgrade is to consider (you guessed it) your weights.
“If you are over your factory GVM number — taking into account every bit of weight you’ll be travelling with [get the vehicle weighed with everything you take on a trip packed: people, gear, water, fuel and so on] — then we recommend a GVM upgrade,” Blake said. If you are over your GVM, this is important to consider as it means you’re beyond the legal limit of your vehicle, which can lead to fines, voiding your insurance and unsafe handling. “If you aren’t pushing over the GVM limit, then get a suspension upgrade with the correct spring choice to suit your setup.”
It’s important to understand your vehicle and van weights so you can determine if a suspension or GVM upgrade is required
If you go for a GVM upgrade without the need for carrying extra weight (i.e., you don’t anticipate exceeding your GVM), this might not suit your setup. GVM upgrades (and the springs involved) are designed to take into account a greater weight, and without the load the suspension might be too stiff. This is why it’s important to have the right spring choice matched to the vehicle weights.
For a full explanation on what a GVM upgrade entails, check out this feature by John Hughes.
Expert advice
To get more information about Tough Dog’s suspension systems, 4WD accessories and GVM upgrades, simply head to the Tough Dog website to find your nearest dealer or contact the head office.
14 Darling Street
Marsden Park NSW 2765
P: 02 9672 8899
E: enquiry@4waysuspension.com.au
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