In the fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight and cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. It also seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level real world usage pattern simulation methodology to validate and correlate the vehicle level targets for micro strain, wheel forces and displacement on suspension components like optimized Z spring, torque rods, pan hard rod & mounting brackets of newly developed light weight two bellow air suspension for buses. The newly developed suspension consist of two air bellows instead of four air bellows along with unique Z spring which replaces conventional parabolic leaf spring and specially designed to take forces in vertical as well as longitudinal direction in combination with torque rod, damper and air spring. To validate the same within stipulated timeline, smart test methodology is developed. This methodology includes road load data acquisition at vehicle level on accelerated durability track with the help of wheel force transducer, string pot & strain gauges. Further the data acquired is analyze with help of N code software followed by target file generation for simulation on test rigs, test setup preparation with strain gauged parts, wheel forces fitment on test rigs set up. Simulation of accelerated durability test track is done on test rigs which includes PID tuning of the servo hydraulic actuators, system identification, drive file generation, simulation comparison for WFT and strain data of selective channels for power spectrum display (PSD) and statistical comparison with target file. After completion of simulation, durability testing is done with new parts.