Product Overview

Summary: This Suspension System Repairs Safe Operating Procedure sets out a safe, consistent method for inspecting, diagnosing and repairing vehicle suspension systems in Australian workplaces. It helps workshops and fleet operators control high‑risk tasks such as working under raised vehicles, handling heavy components and using powered tools, while maintaining compliance with WHS obligations and industry best practice.

Suspension work exposes technicians to a combination of high-risk hazards: vehicles raised on hoists or jacks, stored spring energy, heavy components, and powered tools operating in tight spaces. This Suspension System Repairs Safe Operating Procedure provides a clear, step‑by‑step framework for carrying out inspections, diagnosis and repairs on suspension systems for light vehicles, heavy vehicles and fleet assets. It covers the full task lifecycle, from pre‑job planning and vehicle reception through to test driving, quality checks and documentation, with a strong emphasis on safe lifting, isolation, and the correct use of specialist tools.

Developed for Australian workshops and fleet operators, this SOP helps you demonstrate due diligence under WHS legislation while improving productivity and consistency across your team. It reduces reliance on informal “tribal knowledge” by standardising how suspension repairs are performed, how hazards are controlled (including working under vehicles and handling springs), and how defects, parts and customer authorisations are recorded. The result is fewer incidents, fewer reworks and a more professional, defensible maintenance system that supports both safety and business performance.

Key Benefits

• Ensure safe work practices when lifting, supporting and working beneath vehicles for suspension inspections and repairs.
• Reduce the risk of injury from uncontrolled movement of vehicles, components or stored spring energy.
• Standardise diagnostic and repair steps to minimise comebacks, rework and inconsistent workmanship.
• Demonstrate compliance with Australian WHS laws, manufacturer guidelines and relevant Australian Standards.
• Improve training and onboarding for new technicians and apprentices through a clear, documented procedure.

Who is this for?

• Automotive Technicians
• Heavy Vehicle Mechanics
• Light Vehicle Mechanics
• Workshop Managers
• Fleet Maintenance Supervisors
• Service Advisors
• WHS Managers
• Apprentice Mechanics
• Automotive Repair Business Owners
• Mining and Civil Fleet Maintenance Coordinators

Hazards Addressed

• Vehicle collapse due to incorrect use of hoists, jacks or axle stands
• Uncontrolled release of stored energy from coil, leaf or air springs
• Crush injuries while working under raised vehicles
• Manual handling injuries from lifting or manoeuvring heavy suspension components
• Pinch points and impact injuries when removing or installing suspension parts
• Exposure to noise and vibration from power tools and impact guns
• Slips, trips and falls around workshop bays and hoist areas
• Eye injuries from flying particles, rust, dirt and metal fragments
• Contact with hot components after recent vehicle operation
• Chemical exposure from greases, oils, penetrants and cleaning agents

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Applicable Legislation, Standards and Manufacturer Requirements
• 4.0 Roles and Responsibilities
• 5.0 Required Competencies, Licensing and Training
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre-Work Planning and Job Assessment
• 9.0 Vehicle Reception, Identification and Verification
• 10.0 Hoist, Jack and Support Stand Set-Up and Safety Checks
• 11.0 Suspension System Inspection and Fault Diagnosis
• 12.0 Safe Depressurisation and Control of Stored Energy (Springs, Air Systems)
• 13.0 Removal of Suspension Components (Springs, Shocks, Control Arms, Bushes, etc.)
• 14.0 Installation of Replacement Components and Torque Specifications
• 15.0 Wheel Alignment, Ride Height and Post-Repair Adjustments
• 16.0 Quality Assurance, Test Drive and Final Safety Checks
• 17.0 Housekeeping, Waste Management and Environmental Considerations
• 18.0 Hazard Identification and Risk Control Measures
• 19.0 Emergency Procedures and Incident Response
• 20.0 Documentation, Records and Customer Communication
• 21.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and state/territory equivalents
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS 2550.9: Cranes, hoists and winches – Vehicle hoists
• AS/NZS 1891.4: Industrial fall-arrest systems and devices – Selection, use and maintenance (for work at height on vehicles where applicable)
• AS/NZS 4024 series: Safety of machinery (for workshop plant and equipment)
• AS/NZS 2210.1: Safety, protective and occupational footwear
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 2161 series: Occupational protective gloves