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Old 12-24-2018, 09:24 PM   #41
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Ok, forget about Forest River for any help. They haven't answered yet as it takes them months to conjure up some excuse to lay all on you or anything else! i have 2017 F/T 34QS & the freaking roof had 2 tears in it, they said it was from impact damage, my insurance co, said no way along with 2 RV shops. Was gonna do a lemon law but that take 2 years without being able to use your RV, Ya & the RV industry knows that. They really only have one purpose & thats to make money. Just get it fixed by a reputable trailer repair shop & they can fix it they will. if not think about another brand of axel. Hey just my 2 cents
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Old 12-24-2018, 10:40 PM   #42
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I was going to say poor welding, a weld is usually stronger than the metal it is attached to. Looking at the picture it looks like a cold weld to me, not enough penetration.
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Old 12-24-2018, 11:00 PM   #43
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Poor quality weld .It looks like a mig weld that was trying to fill in a gap from a poorly fitted bracket.There are rubber rods in that tube that are the suspension . Forest River should help you out with this but every body knows the sad stories about RV manufactures.This is really a quality control problem at Dexter axle .Those axles bolt to the frame with 4 big bolts .Only about a 1 hour job to change out a complete axle assembly .If you weld on the tube you will melt the rubber rods .There is a good explanation of how it works on the Dexter Axle website .
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Old 12-24-2018, 11:18 PM   #44
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That weld is ALL that holds the torsion axle. Over time, not matter what you do, its always possible for a weld to crack with 10's of thousands of twists on it all the time. You can see plenty of penetration on the axle tube, and less on the frame.
re-weld by a good welder, should be ok.. CHECK all the others..
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Old 12-25-2018, 07:57 AM   #45
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Originally Posted by dmdomokos View Post
Attached is a picture of what has happened to our front axle on BOTH sides. It has cracked away from the frame, but identically on both sides. The trailer is 3 years old, we haven't gone off road, just long trips to Yellowstone and Oregon. What would be possible causes? And would it be under the 5 year axle warranty? I have sent pics to FR, no response yet.
The cause is poor engineering and manufacturing QC. See post #32
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Old 12-25-2018, 08:01 AM   #46
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The cause is poor to no engineering. The axle tube should not be welded to the frame in that manner. Probably the axle tube should have had a bracket plate welded to it then that in turn welded to the frame.
The axle tube isn't welded to the frame.
The tube IS welded to a bracket which is then in turn bolted to the frame.
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Old 12-25-2018, 08:04 AM   #47
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I would not think that the axle company would claim responsibility for the weld. The axle is fine.
As a welder it looks like a light bead to me. When one broke the other side was affected and broke too. Any good welder can fix it. Just let them know that there is rubber inside and to cool the axle during and after welding.
Pay the weld shop and send the bill to FR.
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Old 12-25-2018, 09:05 AM   #48
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Originally Posted by Steveboe;1993947[B
]I would not think that the axle company would claim responsibility for the weld. The axle is fine.[/B]
As a welder it looks like a light bead to me. When one broke the other side was affected and broke too. Any good welder can fix it. Just let them know that there is rubber inside and to cool the axle during and after welding.
Pay the weld shop and send the bill to FR.
Why not?
The axle company is the one that made that weld!
And while I'll agree the axle itself is ok, their weld to their bracket attached to the axle, is not.
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Old 12-25-2018, 10:20 AM   #49
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Ok I made a reply about F/R earlier & its still the same. After reading & reading it seems to me that say down the road you suspension is starting to sag. I dont know this system, but is there a way to just replace the rubber torsion parts, if so why cant that be done before you would weld it. I agree with the crappy penetration. Actually its hard to see exactly what happened with the weld from the picture, one would have tp look at it from all around. I think a couple more picture would also help, especially from the back side.
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Old 12-25-2018, 01:05 PM   #50
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Just another typical case of poor frame and/or axle design & construction...

If it were me, I'd go talk to a reputable frame & axle shop and get their opinion. I sure wouldn't want to get the axle replaced with another one that has the same substandard welding. It may not cost much to get the welds ground down and re-welded correctly by a certified welder and maybe strengthened as well.

We had a complete TT replaced under warranty due to a defective frame that we discovered the day after we owned it. Initially Lippert said everything was within spec. Then we went to a gov't certified frame & axle shop to get an inspection done. They found all sorts of issues including substandard welding. After sending Lippert and the TT manufacturer a copy of the report, the TT manufacturer said they would replace the entire TT. The frame & axle shop said it was the worst frame they'd ever seen and no manner of remedial work would make it like it should have been in the first place.

Don't expect Lippert or the RV manufacturer to come to the rescue without a fight. But a fight just may not be worth it (literally in $$) not to mention all the aggravation and lost sleep.
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Old 12-25-2018, 02:34 PM   #51
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Why not?
The axle company is the one that made that weld!
And while I'll agree the axle itself is ok, their weld to their bracket attached to the axle, is not.
This^ !! To the OP, have you contacted Dexter and got a reply yet? I'm betting they'll ship new axles and pay for a trailer shop to change them. Don't let an RV dealer do it IMO even if they are bolt on as needs alignment.
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Old 12-25-2018, 03:40 PM   #52
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This^ !! To the OP, have you contacted Dexter and got a reply yet? I'm betting they'll ship new axles and pay for a trailer shop to change them. Don't let an RV dealer do it IMO even if they are bolt on as needs alignment.
As of today, I have contacted Dexter directly, no response. I have contacted Forest River, they say they are waiting for Dexter. I have contacted Good Sam Ext. Warranty, they said it's a frame issue, but I am going back at them as well. I did take the advise of the repair shop, and many of you, and had them do the weld. They beefed it up. They are an RV repair shop, 40 years in business, and said they weld these all the time. It was the only way to get back on the road, we have a trip in two weeks. Now I am going after some reimbursement.
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Old 12-25-2018, 03:51 PM   #53
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THANK YOU BAMA. Dexter makes the entire assembly and Lippert bolts it on to the frame. This is a Dexter issue. If you weld on the axle and ruin the torsion rubber you will not get any warranty. Call Dexter as they will probably replace the entire axle assembly. The Dexter welded mounting brackets should be part of the axle for warranty purposes.
Since the entire axle assembly needs to be replaced, even if I pay to weld the broken axle to the bracket, a replacement axle can still be bolted on later if Dexter pays for it. I fear I will be off the road for quite sometime if I just wait for FR and Dexter. They may not pay for the welding I had done, but maybe replace the axles? Or maybe they pay for the welding then don't cover the axle in the future? Or maybe I just get a big fat "no" to everything. We will see, but for now I had it welded and I am good to go on our next trip in two weeks.
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Old 12-25-2018, 04:23 PM   #54
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Is there a list here on the forum of the TT manufactured with those axles? Thanx
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Old 12-25-2018, 05:55 PM   #55
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As of today, I have contacted Dexter directly, no response. I have contacted Forest River, they say they are waiting for Dexter. I have contacted Good Sam Ext. Warranty, they said it's a frame issue, but I am going back at them as well. I did take the advise of the repair shop, and many of you, and had them do the weld. They beefed it up. They are an RV repair shop, 40 years in business, and said they weld these all the time. It was the only way to get back on the road, we have a trip in two weeks. Now I am going after some reimbursement.
Huh. If these are in fact Dexter axles, they should be covered for at least five years under Dexter's warranty. So... are they in fact Dexter axles? This should be easy enough to tell, as there are big stickers on them at delivery. When the sticker is worn off, the axle is marked with the words "DEXTER AXLE" and a nine-digit serial number that is stamped near the center of each axle tube itself. That SN should tell Dexter all they need to know to replace the axles if still under warranty.

As far as FR and Good Sam, I would think they would point at Dexter and do nothing for you. Your dealer MIGHT help, might not. As Squirrel said, when the axles are replaced it is more than just bolting them up and forgetting about it - they do have to be aligned, and as usual best results on that would be from somebody who has done it before. Preferably, more than once before.

Overall, I would contact the axle OEM after the holidays. This seems clearly to be something that is the definition of warranty repair. If you are telling them that you had them repaired and don't even want replacements, I would think they would be happier still to reimburse you for the cost of the weld.

I am curious, though - Dexter's maintenance manual says not to weld these because of the rubber strands inside. So, how did your welder keep the tube cool during the weld? And for everyone else who says cool the tube during welding, how is that actually done? It still probably burns the rubber strands right adjacent to the weld (?) but as long as that is only for a couple inches, I can see that it would not affect it much. But how do you keep the rest of the tube cool during the weld process?
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Old 12-25-2018, 07:01 PM   #56
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Just go to a good welding shop. Have it rewelded and reinforced if needed and move on. Should get it done for under a hundred bucks and get on with life.
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Old 12-25-2018, 10:18 PM   #57
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Just go to a good welding shop. Have it rewelded and reinforced if needed and move on. Should get it done for under a hundred bucks and get on with life.
In post #52, the OP said they had it rewelded by a repair shop.
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Old 12-25-2018, 11:05 PM   #58
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Herk, does Dexter make the frame or is it a Lippert frame? If it’s a Lippert frame, does Dexter deliver the axles to Lippert for installation before they ship the frame to FR, or does FR put the axles on the frame? Just curious.
Dexter makes axles with the included mount and hubs to Forest River specifications. They deliver them ready to bolt up to the Lippert frame at the factory.

I have a delivery lot invoice around here somewhere that states all the specs for an axle order for that contract of axles (198 axles in the invoice - found it - attached).

I almost got a picture of a truck loaded with axles headed for a "just in time" delivery at the factory; but the DW complained since I was driving at the time.

Pretty amazing that they delivered 198 new built up axles in about 14 days.
Attached Files
File Type: pdf Axle SN 121213978.pdf (106.1 KB, 29 views)
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Old 12-25-2018, 11:43 PM   #59
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Huh. If these are in fact Dexter axles, they should be covered for at least five years under Dexter's warranty. So... are they in fact Dexter axles? This should be easy enough to tell, as there are big stickers on them at delivery. When the sticker is worn off, the axle is marked with the words "DEXTER AXLE" and a nine-digit serial number that is stamped near the center of each axle tube itself. That SN should tell Dexter all they need to know to replace the axles if still under warranty.

As far as FR and Good Sam, I would think they would point at Dexter and do nothing for you. Your dealer MIGHT help, might not. As Squirrel said, when the axles are replaced it is more than just bolting them up and forgetting about it - they do have to be aligned, and as usual best results on that would be from somebody who has done it before. Preferably, more than once before.

Overall, I would contact the axle OEM after the holidays. This seems clearly to be something that is the definition of warranty repair. If you are telling them that you had them repaired and don't even want replacements, I would think they would be happier still to reimburse you for the cost of the weld.

I am curious, though - Dexter's maintenance manual says not to weld these because of the rubber strands inside. So, how did your welder keep the tube cool during the weld? And for everyone else who says cool the tube during welding, how is that actually done? It still probably burns the rubber strands right adjacent to the weld (?) but as long as that is only for a couple inches, I can see that it would not affect it much. But how do you keep the rest of the tube cool during the weld process?
Yes they are Dexter Torflex axles and Dexter was the first contact I tried to make with no answer. I will try Dexter, FR and Good Sam all again after the holidays. So far I haven't gotten an answer other than we are looking into it and will get back to you from FR, who also states they have a 5 year axle warranty on their brochure, but wouldn't confirm what was covered on first contact. I needed to get back on the road soon so I took my repair shop's, and many on this forum's advice, and just got it welded and will deal with what to do next once I hear back from someone. I don't know how they welded it, I had to trust they knew what they were doing from their long history in the repair business. They also repaired my fresh water tank when that fell out of the trailer. I will post for all of you what the answers are from Dexter, FR and Good Sam after a second attempt at a resolution.
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Old 12-26-2018, 07:07 AM   #60
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Makes you sick when you pay that much money for a product and its crap.
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