Level Sensor Retrofit: Simple & Affordable

"For caravan owners or small freight carriers, the tendency to sink into the ground when loaded is a recurring problem. This is especially unpleasant when towing a caravan, as the support wheel can quickly bottom out and hit the road. Besides the risk of damaging or losing the support wheel, this situation can also be dangerous. Those who have a leveling system installed in their vehicle are in a better position. Unfortunately, retrofitting such a system is often not possible or is very complex. In principle, there are several options:"
- Installation of standard parts (if available and possible retroactively --- very expensive).
- Installation of shock absorbers that automatically adjust the vehicle's ride height (affordable, available for a limited number of vehicles; options include Monroe Level Light + Sachs Niveaumat).
- Installation of an air suspension system with automatic leveling (very expensive... but the "luxury version").
- Installation of additional air bladders to support the main spring.

The latter alternative is not necessarily cheap either, as some providers offer automatic leveling via regulated air pressure.
A simple solution is offered by the company MAD. They have a simple system for many vehicles that is inserted into the existing suspension and then inflated with air pressure at the gas station. This prevents the rear of the vehicle from sinking as much when loaded.
http://www.mad-vertrieb.de/luftfedern_frames.htm
The entire system for my Golf cost 268 euros and was completely installed in under two hours.
For the Golf 4, you need to lift the entire car and detach the shock absorbers from underneath. The springs will then almost fall out of their housings on their own. The rubber bellows are depressurized and sealed. Then, they are inserted into the coils of the springs.

Alles weider zusammen bauen. Ready.
The remaining assembly time is used for installing the air hoses and the electrical components (vacuum warning system).
The system should be operated with a minimum pressure of 0.5 bar and a maximum pressure of 2.5 bar. To prevent overpressure in the system, a valve is installed that automatically releases the pressure at 3.5 bar. The low-pressure warning activates at a minimum pressure of 0.2 bar, at which point a buzzing sound will be heard. It's then time to visit the next gas station to "refill" the air.
Those who desire more comfort can install a small air compressor (around ~15 euros) in their car, which can be used to generate the necessary pressure.

Opel offered a similar system in various station wagon models years ago (e.g., the Astra F). I thought this simple version of a leveling system was brilliant.


Here's how it looks when it's installed:

"Hi, that sounds good and looks like it too. I was just wondering if dirt/sand and water wouldn't eventually wear away the feathers over time. Sure, that might take a while, but once the paint on the feather is gone... And what kind of material is that inflatable rubber part made of, that would be durable enough to withstand that abrasive effect? Well, you can't have your cake and eat it too..."
But I'm being pessimistic here, and I actually think the system is good, despite its simplicity! haithamina

haithamina wrote:

... But I'm painting a grim picture here...

No, you're not. I had the same thoughts immediately.

Quote:

... and I think the system is good because of its simplicity!

That's exactly what I thought too.

My initial experiences driving with a fully loaded vehicle have completely convinced me.
After a Teflon spray treatment, the squeaking noises from the rubber bellows have also disappeared.

The material of the bellows is a very durable rubber. It's difficult to work with (I tried to remove a burr with a knife). Nevertheless, it will probably wear out eventually. However, the bellows are available as a single part (I already asked ). Let's see how long it lasts.
I heard from someone in the Netherlands about a vehicle that has already covered 200,000 kilometers.

The inspection at the TÜV (German technical inspection authority) went smoothly, and even there, people were impressed by the simple system. "... If it fails, nothing can happen; the car will simply revert to its standard configuration. ... No problem."

Hello,
Okay, here's the translation:

"By the way, a different question: what is that thing that looks like a crack in the lower left corner of the image?"
I'm sure it's not him, but... haithamina.

haithamina wrote:

... what is that, which looks like a crack in the lower left corner of the image?...

It's not a crack, but rather the corners of a plastic cover. The flash creates a shadow. When the image is zoomed in, it looks like a crack. Here's a picture of the corner from a different angle.