A test and simulation process is presented, for improving the rollover resistance of passenger vehicles by engineering design. The process originates from experience in the analysis of over 60 individual LTV rollover cases, related to litigation. The process involves obtaining vehicle data from test measurements, developing ADAMS-based full vehicle and tire computer models, and validating them against measurements from test vehicle limit maneuver performance. With a validated model for a particular vehicle, a wide variety of limit maneuvers can be conveniently simulated with reasonable accuracy. Also, vehicle performance in a specific rollover crash situation can be iteratively determined to match measured evidence. From the vehicle performance, the driver input is available. This can be used to check redesigns, to see if they remain upright with the same driver input as was involved in the original rollover.