The 2010 Mercedes-Benz E-Class: Chassis and Suspension

The newly developed DIRECT CONTROL suspension with standard-fit amplitude-dependent damping system is one of the major factors behind the high degree of long-distance comfort provided by the E-Class. The shock absorbers adapt to the current driving situation, reducing the damping forces automatically when driving normally with low shock-absorber impulses and increasing the forces up to the maximum as required when cornering at speed or performing evasive manoeuvres. In this way, the chassis and suspension meet driver requirements in terms of road roar, tyre vibration and agility – without ever compromising on active safety.

The shock absorber system works by purely hydromechanical means without the need for sensors or electronics. Its core components are a bypass duct in the shock absorber’s piston pin and a control piston which moves in a separate oil chamber. When the shock-absorber bounce is low, the control piston moves oil through the bypass duct so that a lower damping force is produced at the actual shock-absorber valve. The result is “softer” shock-absorber characteristics and, consequently, a high level of ride comfort. If the excitation of the shock absorber is greater, the control piston moves to its limit position so that oil ceases flowing through the bypass duct, meaning that the full damping force is available.

Mercedes-Benz has modified several aspects of the three-link front suspension with McPherson struts and, as a result, has achieved excellent results in terms of ride comfort. In the interests of optimal axle kinematics, more favourable vibration characteristics and enhanced safety, the lower link level consists of two individual elements that serve as torque and cross struts. As well as offering more precise wheel location, the main benefit of these struts is that they allow better compensation for vibrations caused by tyre imbalance and fluctuations in braking forces than rigid wishbones. In addition, more crumple space is available in the event of a frontal crash. The third front-axle link is the track rod which connects the transversely installed steering gear to the wheels.

The spring struts consist of cylindrical, transverse force-compensating coil springs, double-tube shock absorbers and newly developed three-phase head bearings. In order to further optimise ride comfort, the Mercedes experts have chosen a starkly upright position for the spring strut so as to reduce the forces acting on the torque strut bearing. As a consequence, it was possible to reduce the bearing rigidity, which has a positive effect on the chassis’ tyre/road contact characteristics and rolling characteristics – for example when driving over expansion joints running across the road. The front anti-roll bar is connected to the spring strut, which is likewise actively involved in locating the front wheels.

Intelligent use of aluminium and steel reduces the weight of the front axle by twelve percent compared to the outgoing model. The forwards-slanting torque struts and the cross struts are made of aluminium.