Jayco Spring

Submitted: Tuesday, Sep 03, 2013 at 19:34
ThreadID: 104172 Views:3146 Replies:7 FollowUps:5
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I have a broken spring on my 2011 dual axle off road Jayco discovery.
Inside nut 15/16 outside head 11/16 welded on! What the hell!!
Can anybody help please? (What is the setup and how do I get it apart)
Appreciate any help thanks
Peter
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Reply By: MUZBRY- Life member(Vic) - Tuesday, Sep 03, 2013 at 19:55

Tuesday, Sep 03, 2013 at 19:55
Gday Peter
Do you have a photo?

Muzbry
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Follow Up By: Member - Peter M2 (NSW) - Tuesday, Sep 03, 2013 at 20:22

Tuesday, Sep 03, 2013 at 20:22
No I haven't but could do one tomorrow thanks
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Reply By: Member - Warrie (NSW) - Tuesday, Sep 03, 2013 at 20:00

Tuesday, Sep 03, 2013 at 20:00
Peter, we need more info. Is it snapped off near the bolt and undrivable or is it just a crack through a leaf? Are you at home or in woop woop and remote from a repairer? What driving were you doing when it broke?
Maybe you could angle grind the weld away and half destroy the bolt but still be able to undo it...... W
Warrie

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Reply By: Member - Peter M2 (NSW) - Tuesday, Sep 03, 2013 at 20:21

Tuesday, Sep 03, 2013 at 20:21
We are at home so that is ok.
Top leaf broken about 100ml from the rear bolt.
Why does it have a 15/16 bolt on the inside and a 11/16 on the outside. I can grind the outside head off but does anyone know what I will find.
I am a bit confused as to why two different sizes on the one bolt.
thanks
AnswerID: 517593

Reply By: Michael ( Moss Vale NSW) - Tuesday, Sep 03, 2013 at 20:44

Tuesday, Sep 03, 2013 at 20:44
Peter, its not two years old! Ring the agent you bought it from and demand you have it fixed at their cost. You have consumer rights (Australian Consumer Rights) way past the (probably) 12 months warranty they tell you have. Michael
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Follow Up By: Member - Peter M2 (NSW) - Wednesday, Sep 04, 2013 at 10:51

Wednesday, Sep 04, 2013 at 10:51
Thanks a lot Am ringing agent today
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Reply By: desray (WA - Tuesday, Sep 03, 2013 at 21:03

Tuesday, Sep 03, 2013 at 21:03
I have a Jayco Outback Hawk. The shackle pins at the end off the springs were also welded to the chassis. I had to use a angle grinder to cut the welds and renew the pins/bolts.
AnswerID: 517596

Follow Up By: Ross M - Wednesday, Sep 04, 2013 at 10:47

Wednesday, Sep 04, 2013 at 10:47
desray
You can't have shackle bolts welded to the chassis otherwise the shackle won't move.
Perhaps it is the "hanger" bolts, the fixed ends, which are being referred to and not shackle bolts at all.
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FollowupID: 797319

Follow Up By: desray (WA - Wednesday, Sep 04, 2013 at 22:26

Wednesday, Sep 04, 2013 at 22:26
splitting hairs ??? the bolts holding the springs were welded in ,, hangers or whatever still welded. still needed a angle grinder to remove them .
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Reply By: Member - Allan H (NSW) - Wednesday, Sep 04, 2013 at 06:51

Wednesday, Sep 04, 2013 at 06:51
Hi Peter,
Just replaced all shackles and rockers on our Jayco Sterling Outback cut the weld and remove bolts, no big deal. Jayco had issues with the pins turning in the mounts which made the pin holes elongate and create movement, this why they need to be welded back in place when you replace them. I replaced the pins with greasable pins with nylon lock nuts and drilled holes in bolts to fit split pins. I took our van to an engineering place to have the bolts heads welded once replaced. Make sure they use a welder that has low heat not arc.
Not sure if you have Alko suspension after spending quite some time researching before doing the job new springs x 4 would cost about $500 including rockers and bolts.
Hope this helps
Allan
AnswerID: 517605

Follow Up By: Member - Peter M2 (NSW) - Wednesday, Sep 04, 2013 at 10:55

Wednesday, Sep 04, 2013 at 10:55
Thanks so much for your reply
Yes it is alko suspension.Will be speaking to the Jayco dealer in the next couple of days.
If no luck with them will do what you did
Thanks so much Peter
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FollowupID: 797321

Reply By: Member - Bruce C (NSW) - Thursday, Sep 05, 2013 at 18:13

Thursday, Sep 05, 2013 at 18:13
Hi Peter,

It could be that the spring that broke was faulty. I had the same thing happen on our previous van, a Gazal Champion, and I replaced the springs with heavier units as I reasoned that the springs would have been operating close to max loading to break. I could have been wrong but in all my life of motoring I have never had a spring break on any other vehicle I owned, except that one occasion.

I now have a Jayco Sterling.
Think about replacing the springs with heavier units for peace of mind. Take one spring to your nearest trailer repair parts crowd as a sample to get the right units if deciding to go that way.

To get the welds off the shackle bolt use a fine cutting disc in a 100mm grinder and try not to take off any more metal than needs be to get the bolt out.

One good weld tack when replacing the bolt should do the job. Not too much heat or it will melt the bushes. Keep a rag soaked in water handy when welding to cool the job so the heat does not penetrate too far.

Cheers, Bruce.
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