Axle supports cracked - Help please

[gectisme]

So, I just got done saying how we haven't had any issues that have kept us off the road and then of course it happens. Man did I jinx myself. I had a brake failure, where it shorted to ground, OK, that isn't that big a deal. The issue is when I was ohm'ing things out with the DVM I looked up and saw a crack in a weld. After further inspection there are multiple cracks in welds on one side, on both axles. On the other side each axle has a crack in the metal just above the weld. This is where I need help, is this a time that the axles should be replaced or is just welding them the fix?
Thanks in advance for any input.

[A32Deuce]

Find someone that does welding and have it done. Mark every spot, around not on. If you go to the dealer, may take weeks. Should have no problem finding a qualified welder. That's what I would do, course I would do it myself.

[D W]

Originally Posted by gectisme

So, I just got done saying how we haven't had any issues that have kept us off the road and then of course it happens. Man did I jinx myself. I had a brake failure, where it shorted to ground, OK, that isn't that big a deal. The issue is when I was ohm'ing things out with the DVM I looked up and saw a crack in a weld. After further inspection there are multiple cracks in welds on one side, on both axles. On the other side each axle has a crack in the metal just above the weld. This is where I need help, is this a time that the axles should be replaced or is just welding them the fix?
Thanks in advance for any input.

As a 2016, it should be under warranty. Have you contacted the MFGR with these pics? Looks to me to be inferior welds. A good welder is all that is needed to clean-up this mess. It can't hurt to try and get this repaired under warranty. Worth a try.

[gectisme]

A32Deuce and D_W, thanks for the info. I don't know much about welding and iron, although I did do some welding in Metal Shop back in High School, but that was a long time ago and I probably should have listened more. I am worried the same issue will come back down the line that's why I was wondering if the axles should be replaced all together. I take it in tomorrow so if they say they can fix it by just welding, I will go with that.

The Rockwood warranty lady already told me both the brake and cracked axles will be covered by warranty. I have to have an independent shop work on it because I am too far away from any Forest River Dealer being on the road.

[youroo]

Your Dexter Tork Flex axles "Cant be Welded On" as per Dexter! Welding will damage the Rubber inside the axles! NEW axles are the answer! Youroo!!

[A32Deuce]

That takes care of that. Any cracks not on the axles can be welded though.

[gectisme]

Originally Posted by youroo

Your Dexter Tork Flex axles "Cant be Welded On" as per Dexter! Welding will damage the Rubber inside the axles! NEW axles are the answer! Youroo!!

youroo, thanks for that! I will call Dexter first thing in the morning to see what are my options then.

[rockfordroo]

Originally Posted by youroo

Your Dexter Tork Flex axles "Cant be Welded On" as per Dexter! Welding will damage the Rubber inside the axles! NEW axles are the answer! Youroo!!

Question: If you can't weld on the axles, how did they get welded in the first place?

[youroo]

Originally Posted by rockfordroo

Question: If you can't weld on the axles, how did they get welded in the first place?

Easy the welding is performed "Before" the torsion bar and rubber is inserted into the Axle Tube! Youroo!!

[rockfordroo]

Originally Posted by youroo

Easy the welding is performed "Before" the torsion bar and rubber is inserted into the Axle Tube! Youroo!!

Once inserted, it can't be removed?

[gunpro]

As a professional welder the axels should not be welded on, replace only. The other cracks are the result of stress and the source of the stress should be removed. When the body/frame cracks are repaired they should be welded from one side and ground out from the opposite side and welded 100%. Follow this procedure you will have a successful repair

[Bama Rambler]

Originally Posted by rockfordroo

Once inserted, it can't be removed?

Yes, they can be replaced, but it costs as much to rebuild them as a new axle costs, so no one does it.

[youroo]

Originally Posted by rockfordroo

Once inserted, it can't be removed?

Sure can,and a quick way is to weld on the tube which will burn/weaken the Rubber cords and it will "Fall apart",Now without the "High $$$$ Hydraulic Machine" to reassemble with new cords that you Can't buy,what are you going to do? Buy NEW axles! Youroo!!

[rockfordroo]

So how do they weld on the tubes in the first place?

[5picker]

Originally Posted by rockfordroo

So how do they weld on the tubes in the first place?

Welding is done before the compression insertion of the rubber torsion bars. (cords)

[rockfordroo]

Originally Posted by 5picker

Welding is done before the compression insertion of the rubber torsion bars. (cords)

Thanks.

[Bama Rambler]

As Youroo said in post #9, they do all the welding before they press the rubber bars and center shaft into them.

Here a video that shows them pressing one together.

Torsion Axle

[youroo]

Originally Posted by gectisme

youroo, thanks for that! I will call Dexter first thing in the morning to see what are my options then.

Did this happen? What did they say? Youroo!!

[gectisme]

Originally Posted by youroo

Did this happen? What did they say? Youroo!!

youroo, you win the prize! Thanks again. Dexter said the axles need to be replaced. We are on the road and need to get moving so tomorrow I am driving the truck back to Indiana to pick up the axles from FR and getting them replaced on Friday, (didn't want to wait till Monday or Tuesday for shipping). We were lucky that FR was able to come up with a couple of them because it was going to take time for Dexter to build them. I wanted to upgrade to next bigger size but FR said that would void the warranty and more importantly no longer assist in getting them replaced.

This is our first TT and didn't pay attention to axle ratings and weights and stuff other than what we can carry. Now that I see these are 4000 lb axles, that is right at where the trailer weighs loaded up. I would have thought there would be some sort of margin for safety and durability but I guess not...

Once they had the brake drum off, you could see the weld was completely broken through in one place. Also, the "lucky brake" that went bad had the magnet completely torn off it's supports so I am happy the new axles are coming complete with new brakes. It's the "lucky brake" because if it had not caused trouble I would have never been under the trailer to notice the broken welds. It's just too bad it didn't happen just before arriving at the Goshen Rally instead of right after.

Anyway, hope to have the new Axles and new brakes installed on Friday and be on the road again, either Friday afternoon/evening or Saturday morning.

Check those axles as part of your maintenance if you have a WJ. I surely will.

I also have to say, so far FR Warranty Department has been great to deal with and has been on top of this since I reported it to them. Thank my lucky stars we went with the 2nd year.

[youroo]

gectisme, make sure whoever installs your New axles "Adjusts the Brakes" on all 4 wheels! Don't let them say "the brakes are Self adjusting,after you drive a while they will be Fine"! Also have them give you a Dexter Book on proper "Burnishing" of your New brakes! Also "Check/Add" the proper wheel bearing Lube to your NEW axles,they often "Only have enough Lube for Assembly" think "Safe or Sorry"! Have a safe trip back to Cal! Regards Youroo!!