Dexter brake failure in Rockwood

RockwoodUL2604 · 11-13-2018, 08:09 AM

I have two years and 6300 miles on my 2017 Rockwood TT 2604ws. Durning a routine brake and bearing inspection I found the right front brake completely shot. Not sure of the root cause but my guess is a failure of the never adjust brake system resulting in over adjust, overheat failure. Did not know I had a problem until I inspected. Just came back from a 2500 trip so I was lucky.

Ordered replacement factory parts from e trailer and were delivered in 3 days. Filled a warranty claim with Dexter via email and they gave me a claim number and approved the expense in less than 24 hours and I had a check in less than a week. Overall good customer service.

Has anyone else had this issue. Not sure what I could have done about it but I will start doing inspections and servicing once per year as recommended.

TheWolfPaq82 · 11-13-2018, 08:16 AM

Where did all that grease...or whatever is caked on everything come from ??

RockwoodUL2604 · 11-13-2018, 09:00 AM

I would say it is a mixture of grease and brake dust. Hot drum cause the seal to fail and the grease to soften and flow into the drum.

**Bama Rambler** · 11-13-2018, 09:25 AM

The pads don't look like they have much wear, so I'm not sure it's an over-adjustment failure. It appears to be an incorrect assembly failure and that's probably why Dexter didn't give you any push back.

Have you ever had them apart before?
Have you ever used the EZ-Lube system?

RockwoodUL2604 · 11-13-2018, 12:30 PM

Never pulled the drums off to inspect brakes. Also first time I added grease using EZ lube. Other three brakes were fine, this was just a single failure.

SailorSam20500 · 11-13-2018, 12:47 PM

When you did your lube job, how easy was it to spin the wheels?
I've had mine jacked up a few times and each time at least one of the wheels had over-adjusted brakes. The wheel was difficult if not impossible to spin. I had also noted that the difficult wheels always ran a little warmer than others - based on an infra-red thermometer readings during stops while towing.

After "un-adjusting" the wheels a few times, I threw in the towel and upgraded to disk brakes. So far, no more issues and the brakes work a LOT better. On hard stops, testing the brakes, it now seems like the trailer helps stop the truck.

moff34 · 11-13-2018, 02:55 PM

We have a 2016 Rockwood 8329ss with Dexter axles and brakes. We were returning from a 6500 mile trip this past May and were 35 miles from home, going 50 mph, when a driver pulled out in front of me. I had to lock up the brakes to keep from hitting them. Upon arriving at home I immediately used my infrared thermometer to check all four drums. The right side drums were twice the temperature as the left side drums. The left sides were at their normal operating range when compared to the temps I found at every stop on our trip.

When I pulled off the right side drums pieces of the brake assembly, from both wheels, fell onto the ground. You can see the damage in the pictures below.

I did some googling and I found other threads where this same type of damage occurred to Dexter brakes, predominately to the right side assemblies.

I called Dexter and explained what had happened. The Customer Support person was very nice and asked for pictures. He stated that although my trailer was out of the two year warranty period by six months, they would send me, free of charge, new brake assemblies for all four wheels, four new rear seals, and new drums and bearings for the right side.

In my opinion, I believe Dexter knows they were having a problem with this brake design and was one of the reasons they were willing to give me new parts. I also noticed a design change with one heavier spring replacing the two small lighter springs at the top of the assembly, which you can see in the picture below.

If you have Dexter brakes made around this time, I strongly suggest you keep a close watch on them with an infrared thermometer while traveling, and if you have never pulled the drums, do so.

If I have further issues, I plan to get rid of the Dexter Nev-R-Adjust brake assemblies and replace them with either disc brakes or manual adjust brakes.

The pictures below are, in order, the right rear, the right front, the parts from the right rear, and the new assembly.

Bluepill · 11-13-2018, 03:24 PM

@moff34 Thanks for posting.

Another heads-up on brakes: When I inspected my new camper, I found 4 places where the wiring was just sitting on a sharp edge of a frame crossmember.

Constant rubbing as the camper runs down the road in time could rub through the wire insulation and short out the brake system (Blue wire in photo), causing a complete loss of trailer brakes.

My solution was to cover the wires with poly water tubing.

**Bama Rambler** · 11-13-2018, 03:28 PM

That new bottom assembly is a different design that the top two, so maybe they've fixed the problem.

moff34 · 11-13-2018, 03:56 PM

Quote:

Originally Posted by Bama Rambler

That new bottom assembly is a different design that the top two, so maybe they've fixed the problem.

I noticed that right away. I sure hope that fixes the issue. From my online research I believe it is the self-adjusting feature, but why is it predominately only the right side brakes having failures?

My original intent was to go with manual adjustment assemblies, but since Dexter was willing to provide replacement parts for free, I decided to give them one more chance.

TheGerman · 11-13-2018, 03:56 PM

It looks like in both cases the magnet came loose and and then tumbled around the inside of the drum. I don't think it was the nevr-adjust causing the issue.

babock · 11-13-2018, 04:37 PM

Quote:

Originally Posted by RockwoodUL2604

Never pulled the drums off to inspect brakes. Also first time I added grease using EZ lube. Other three brakes were fine, this was just a single failure.

Another story of why you never want to use the EZ Lube system.

luckieman · 11-13-2018, 04:47 PM

I also have had issue with the drum brakes and switched to disc.A word of warning to all dexter disc brake system --check the retaining pin on the calipers asap if you have the 2017 or older rigs (check newer also just in case the older system was installed . the earlier caliper pin used in retaining the pads is held on by a cheap wire and the pin will back out and damage your wheels and toss the pads resulting in a total failure of the system and loss of brakes (as mine did). dexter has since switched a lock nutted pin . due to other failures of the dexter suspension I replaced the hole suspension with the Moryde I.S. and used the Kodiak disc brakes . been the best choice -very nice and reliable and smooth to boot . disc are the best way to go when done right

babock · 11-13-2018, 11:00 PM

On my boat trailer I went with Kodiacs. Seems like the best disc brake to me.

DouglasReid · 11-14-2018, 05:20 AM

I don't believe the failure was caused by over greasing, but I DO think someone pumped in too much grease, blew the seal and that is why the grease is everywhere.

Even just one or two pumps a year will eventually blow the seals, Grease IS NOT consumed in use.

RockwoodUL2604 · 11-15-2018, 01:01 PM

After feedback I got on this thread I decided to pull the remaining three drums and take a look. The first one I pulled was the right rear. Found the magnet was damaged and had come off the arm. Called Dexter and they are sending me the remaining 3 brake assemblies and seals. Looks like what I am getting is the new design. I was under the impression that my brake warranty was two years from date of purchase but the customer service rep told me it is now 5 years. I can't say I noticed that I was having a stopping issue even with the right front brake out of service. I will keep an eye on this with the temperature gun and continue to clean lube and insect once per year until I get more confidence that it is resolved

RockwoodUL2604 · 11-21-2018, 10:41 AM

Dexter sent me the three new brake assemblies via Fed Ex in three days. All good so far. When installing the last brake assembly I found it was put together incorrectly (see pictures). Working on cars on and off for 50 + years and having done many drum brake jobs on autos, this was not a big deal to correct. I wonder how things like this get out the door in the first place. The cost of inspecting these things and catching problems early are much less than fixing someone's trailer down the road.

Bluepill · 11-21-2018, 02:12 PM

FR and its vendors seem to think that the whole RV owner customer base should be their "Beta Testers".

They must have figured if it's good for Microsoft, it's good for them too.

**Herk7769** · 11-22-2018, 08:30 AM

Big recall going on by Dexter and FR regards late model axle assemblies that can cause wheel lockups and brake fires.

https://static.nhtsa.gov/odi/rcl/201...8V678-1277.pdf

https://oemdtc.com/1496/missing-bear...-trailer-axles

https://www.automotive-fleet.com/725...xle-assemblies

https://www.automd.com/recall/dexter-axle_m/

https://www.automd.com/recall/campaign_c493/

https://www.automd.com/recall/campaign_c494/

HeavyPuller · 12-22-2018, 10:18 AM

Yep I had the same issue on Flagstaff 832 IKBS. Removed the hub to see why all the grease was coming out of the back side and when I pulled the hub everything fell out in pieces. Only one of the four was in pieces but the other three needed lots of grease removal/cleaning. Dexter Customer service did send me a reimbursement check. Thinking now about seeing if Dexter will replace the other three. I'm afraid the other three will do the same. Your thoughts on requesting replacement of the other three. I know it won't hurt to ask but just the heck with it and go with disk brakes or "manual" adjustable?

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