AirTec provides professional repair of all types of air springs (airsprings) used in air and adaptive suspension systems.
We deliver complete system-level service, not just replacement of individual components.
👉 AirTec is the only company in Bulgaria offering air spring repair using original OEM-grade rubber, identical to that used for first installation.
Repair Process (Reconditioning)
1. Disassembly and Cleaning
After removal, the air strut is fully disassembled into:
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air spring (airspring)
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shock absorber (passive or electronically controlled)
2. Inspection, Measurement, and Fault Identification
A detailed inspection and precise measurements are performed after disassembly.
The most common causes of failure are:
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cracked or worn rubber bellows
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leaking shock absorber, where hydraulic oil damages the rubber
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shock absorber failure leading to excessive peak loads on the air spring
3. Shock Absorber Testing (Shock Absorber Dyno)
🔴 Every shock absorber is tested on an electromagnetic EMA shock absorber dyno with laboratory-grade OEM characteristics, regardless of customer complaints.
A faulty shock absorber is the most common cause of air spring failure.
✔ Air spring repair only makes sense if the shock absorber is fully functional.
✔ We provide measured data and graphs, not subjective “by-feel” diagnostics.
The EMA dyno allows precise evaluation of shock behavior under loads and speeds that accurately reproduce real road conditions.
4. Component Replacement – OEM Standard
At this stage, all required components are replaced:
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air spring rubber bellows (OEM specification)
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seals
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dust covers
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steel retaining rings
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bushings and other load-bearing elements
OEM Quality Without Compromise
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materials designed for original equipment use
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optimal elasticity and flexibility
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long-term durability and stable performance across temperature ranges
✔ 100% Made in Europe – Assembled by AirTec
5. Elastomer Testing and OEM Comfort Control
After replacing all elastic components, quality control is performed using an elastomer testing system, allowing precise evaluation of:
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all suspension bushings
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all rubber and elastomeric top mounts
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elastic load-bearing elements within the air spring
This test measures the actual mechanical behavior of the elastomer under load, not just its visual condition.
Once the air spring is fully assembled, the spring rate is also measured and verified.
This ensures that the air spring operates within the original OEM specification range, guaranteeing factory-level comfort, correct ride height, and balanced vehicle behavior.
➡️ This control step eliminates overly stiff, unstable, or incorrectly behaving air suspensions commonly associated with improper repairs.
6. Crimping – The Most Critical Step
Crimping ensures a hermetic connection between the rubber bellows and metal components under:
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normal operating pressure of 8–10 bar
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significantly higher peak pressure loads
AirTec uses a computer-controlled Uniflex Hydraulik crimping press, which:
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automatically monitors applied force
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controls crimp diameter to hundredths of a millimeter
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manages deformation speed
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stops the process automatically if parameters exceed limits
This prevents:
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rubber damage
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deformation of metal components
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future air leaks or failures
➡️ Nothing is left to chance, because quality is never accidental.
7. Assembly and Pneumatic Testing
After repair, the air spring and shock absorber are assembled into a complete air strut.
Before installation, each unit undergoes:
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one-hour pneumatic pressure testing at 11 bar
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micro-leak detection
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final quality inspection
Installation, Road Test, and Final Diagnostics
After reinstallation:
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careful assembly without mechanical stress
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road testing
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computer diagnostics
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full system verification
✔ All procedures are carried out on-site at AirTec.
Package Services
We recommend our package service solutions, which include:
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diagnostics
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repair
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installation
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testing
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full warranty coverage
➡️ Less hassle, maximum reliability, and long-term performance.
