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In today's world, there are a prominent number of weight and cost reduction projects within the vehicle engineering development activities. Regarding this phenomenon, a complete optimization study is applied to a leaf spring assembly, which has 4 leaves and which is used in heavy duty trucks, by reducing the number of leaves down to 3 together with weight and cost reductions. At the first step of the project, the stiffness of the leaf spring is calculated with in-house software based on mathematical calculations using the thickness profile of the leaves. Then the results of these calculations are compared with non-linear elastic leaf spring calculations which are conducted with FEA. This elastic leaf spring finite element model is transferred into Multi-Body-Simulation (MBS) model in order to determine the forces acting on the leaf spring.