Over recent years the progress in actuator and microelectronics technology has made intelligent suspension systems feasible. Based on conventional vane hydraulic damper, a new vane magneto-rheological fluid (MRF) damper with fail-safe capability is designed. Firstly, the mathematical model of damping moment is deduced based on the parallel-plate model and Bingham model of MR fluids. Secondly, some influence factors of damping adjustable multiple are analyzed to provide some ways for augmenting the damping adjustable multiple under the condition of keeping initial damping moment invariable. Finally, the magnetic circuit is designed, and magnetic field distribution is simulated with the magnetic finite element analysis software-AN,SOFT. The theory and simulation results confirm that the damping adjustable range of vane MRF damper can meet the requirement of heavy vehiele semi-active suspension system.