ELKHART — Lippert Components today addressed reports of leaking axles resulting in grease contamination of brake pads and rotors by noting the problems are likely impacting only one-tenth of 1 percent of travel trailer and fifth wheel owners using the firm’s products.
The company makes chassis for a variety of RV manufacturers and Lippert’s staff estimates its chassis form the foundation of more than half of all towable recreation vehicles.
The issue surfaced a few weeks ago on a Grand Design owners forum where an unofficial poll revealed that 74 percent of the 164 owners responding to the survey were reporting their axle seals had failed and they had grease on their brakes. Another 12 percent indicated they didn’t have that problem, and 14 percent weren’t sure.
However, simply asking the question generated more than 500 comments. The forum question can be found at granddesignowners.com.
Grand Design officials told RV Daily Report the company acquires chassis from Lippert Components and that their chassis are not specially designed exclusively for Grand Design.
Andy Murray, the vice president of RV sales for Lippert Components, told RV Daily Report that his company is, indeed, aware of the problem and aware of the conversation among Grand Design owners.
However, he noted Lippert technicians have not witnessed the seals cracking, and that the company does not believe it to be a contributing factor to the problem. The company has produced a frequently asked questions sheet concerning axle grease and brake contamination. In it, Lippert notes that the appearance of grease on wheels may not necessarily be the result of broken axle seal, but rather residual grease remaining from the manufacturing process that should have been wiped clean.
“Brake contamination occurs only if the braking components are saturated with excess grease,” the FAQ sheet explains.
Lippert explains there may be several causes for grease to appear on wheels, including:
·A leaking grease seal that can cause excess grease to coat braking components.
·Improper disassembly of a hub can extract grease from the seal causing the braking components to be saturated.
·Failure to properly clean and reassemble a hub can cause excess grease to appear.
·Failure to strictly adhere to service procedures when servicing axles can cause excess grease.
·Use of a powered grease gun to fill the hub cavity can cause grease to get past the seal or push the seal out of the hub bore.
It is normal to have a small residual amount of grease on the exterior of a new hub. Most of the time, simply wiping off the residual grease is an appropriate solution, the company explained.
However, it is not normal for a hub to continue to weep grease after its initial installation. Excess grease can coat the brake pads, magnets and braking surfaces inside of the hub, causing brake contamination. If this occurs, there will be noticeable diminished braking capability.
RVers who suspect their braking capability has been reduced — especially if they continue to see grease on their wheels after wiping it clean — should have the hub checked by a qualified service provider.
Servicing wheels and axles should be performed ONLY by trained technicians, Lippert warned, because disassembling the hub will likely break the grease seal and will result in contamination of the brakes. Should the hubs have to be pulled for any reason, then Lippert highly recommends replacing the grease seals and wiping the brakes with a commercial brake cleaner to remove any grease residue.
Possibility of recall?
Some Grand Design owners have reported the issue to the National Highway Traffic Safety Administration fearing that grease leaking onto the brakes creates a dangerous safety issue. The owners who contacted RV Daily Report, have not heard anything back from NHTSA.
However, Murray said Lippert Components has reviewed the issue with NHTSA personnel in detail, and the outcome of that discussion was a focus on owner education related to the problem, and continued process improvement int he manufacturing and shipping of chassis. The company developed the axle grease/brake contamination FAQ to assist with consumer education.
“We have made significant and ongoing improvements to our processes,” he explained. “Based on our warranty claim data, the overall frequency of this issue was less than 1/10th of 1 percent across all our products for the past 12 months of activity. That is significantly lower than results reported in the poll on the owners’ forum.”
In the meantime, Lippert Components is covering the cost of inspections for anyone concerned that this issue impact their RVs, and the firm is covering the cost of any necessary repairs that are identified as a result of the inspections.
“It is EXTREMELY important that disassembly of the hub for detailed inspection be handled only by qualified technicians, as improper handling can easily create this issue by unknowingly disrupting the seals or spreading grease unintentionally,” Murray warned.
Maintenance is important
Lippert stressed that axles should be inspected and serviced every 12 months or 12,000 miles, and that brakes need to be inspected and adjusted every 3,000 miles.
The company provides more information on service schedules and inspection guides within its owners manuals.
However, customers who have concerns about the possibility of grease leaking onto brakes are encouraged to contact Lippert at 574.537.8900 or by email at customerservice@lci1.com.
Above from Industry Trade RV Daily Report - No opinion on my part - just information.
Grease seal/over-packing threads have been going on the GD forum for far longer than the one linked above. When we had our suspension system replaced by MOR/ryde in Elkhart last September, three of the four Lippert brake assemblies had grease on the braking surfaces - and those axles were manufactured in early 2015. While in the area, we spoke face-to-face with two people who were recent former employees of LCI - one worked in the quality arena for the axle and suspension division. The problems were traced to multiple causes... a "perfect storm" of process and product glitches, if you will. The hubs were being over-packed and then placed on plywood pallets for transport to the next assembly point. Sliding the hubs across the plywood to remove them contaminated the brake drums with grease from inside the hubs. After assembly, the use of cheap, Chinese made grease seals with a tendency for failure further contributed to the problem. Add to this the fact that the brakes were non-self-adjusting and you have a recipe for disaster. The problem is also not limited to axles shipped to Grand Design. There are numerous reports on the Forest River and other forums of the same issues.
It is my understanding that GD has since specified self-adjusting brakes on the chassis supplied for their products, which should help. Lippert claims to have changed their packing and assembly processes. On the GD forum, an increasing number of new owners are insisting that their selling dealers disassemble, inspect, and service the bearings, grease seals, and brakes as part of the PDI process before delivery. In general, Grand Design is known for very good customer service and is working with owners who have "greased brake" problems after the sale. I think it's shameful, though, that Lippert should imply that part of the problem is "owner education" and post-sale service procedures when it's clear that the majority of the units with problems come from the Lippert factory that way. Perhaps I'm too steeped in the teachings of Dr. W. Edwards Deming (the man who "wrote the book" on quality management), but - even though the stated overall failure rates are low - brakes are just too important to accept any significant degree of failure.
I have written extensively in other threads (mostly on the GD forum) about the circumstances that lead us to spend the money for the MOR/ryde independent suspension. It is no secret that I am not a Lippert "fan boy." That said, I will admit that LCI has treated us very well (in concert with Grand Design) related to some furniture warranty issues. I just wish they (Lippert) would bite the bullet and make the necessary changes to keep this dangerous brake situation from occurring.
Lippert addresses reports of leaking RV axles
February 17, 2017
ELKHART — Lippert Components today addressed reports of leaking axles resulting in grease contamination of brake pads and rotors by noting the problems are likely impacting only one-tenth of 1 percent of travel trailer and fifth wheel owners using the firm’s products.
The company makes chassis for a variety of RV manufacturers and Lippert’s staff estimates its chassis form the foundation of more than half of all towable recreation vehicles.
The issue surfaced a few weeks ago on a Grand Design owners forum where an unofficial poll revealed that 74 percent of the 164 owners responding to the survey were reporting their axle seals had failed and they had grease on their brakes. Another 12 percent indicated they didn’t have that problem, and 14 percent weren’t sure.
However, simply asking the question generated more than 500 comments. The forum question can be found at granddesignowners.com.
Grand Design officials told RV Daily Report the company acquires chassis from Lippert Components and that their chassis are not specially designed exclusively for Grand Design.
Andy Murray, the vice president of RV sales for Lippert Components, told RV Daily Report that his company is, indeed, aware of the problem and aware of the conversation among Grand Design owners.
However, he noted Lippert technicians have not witnessed the seals cracking, and that the company does not believe it to be a contributing factor to the problem. The company has produced a frequently asked questions sheet concerning axle grease and brake contamination. In it, Lippert notes that the appearance of grease on wheels may not necessarily be the result of broken axle seal, but rather residual grease remaining from the manufacturing process that should have been wiped clean.
“Brake contamination occurs only if the braking components are saturated with excess grease,” the FAQ sheet explains.
Lippert explains there may be several causes for grease to appear on wheels, including:
· A leaking grease seal that can cause excess grease to coat braking components.
· Improper disassembly of a hub can extract grease from the seal causing the braking components to be
saturated.
· Failure to properly clean and reassemble a hub can cause excess grease to appear.
· Failure to strictly adhere to service procedures when servicing axles can cause excess grease.
· Use of a powered grease gun to fill the hub cavity can cause grease to get past the seal or push the seal out
of the hub bore.
It is normal to have a small residual amount of grease on the exterior of a new hub. Most of the time, simply wiping off the residual grease is an appropriate solution, the company explained.
However, it is not normal for a hub to continue to weep grease after its initial installation. Excess grease can coat the brake pads, magnets and braking surfaces inside of the hub, causing brake contamination. If this occurs, there will be noticeable diminished braking capability.
RVers who suspect their braking capability has been reduced — especially if they continue to see grease on their wheels after wiping it clean — should have the hub checked by a qualified service provider.
Servicing wheels and axles should be performed ONLY by trained technicians, Lippert warned, because disassembling the hub will likely break the grease seal and will result in contamination of the brakes. Should the hubs have to be pulled for any reason, then Lippert highly recommends replacing the grease seals and wiping the brakes with a commercial brake cleaner to remove any grease residue.
Possibility of recall?
Some Grand Design owners have reported the issue to the National Highway Traffic Safety Administration fearing that grease leaking onto the brakes creates a dangerous safety issue. The owners who contacted RV Daily Report, have not heard anything back from NHTSA.
However, Murray said Lippert Components has reviewed the issue with NHTSA personnel in detail, and the outcome of that discussion was a focus on owner education related to the problem, and continued process improvement int he manufacturing and shipping of chassis. The company developed the axle grease/brake contamination FAQ to assist with consumer education.
“We have made significant and ongoing improvements to our processes,” he explained. “Based on our warranty claim data, the overall frequency of this issue was less than 1/10th of 1 percent across all our products for the past 12 months of activity. That is significantly lower than results reported in the poll on the owners’ forum.”
In the meantime, Lippert Components is covering the cost of inspections for anyone concerned that this issue impact their RVs, and the firm is covering the cost of any necessary repairs that are identified as a result of the inspections.
“It is EXTREMELY important that disassembly of the hub for detailed inspection be handled only by qualified technicians, as improper handling can easily create this issue by unknowingly disrupting the seals or spreading grease unintentionally,” Murray warned.
Maintenance is important
Lippert stressed that axles should be inspected and serviced every 12 months or 12,000 miles, and that brakes need to be inspected and adjusted every 3,000 miles.
The company provides more information on service schedules and inspection guides within its owners manuals.
However, customers who have concerns about the possibility of grease leaking onto brakes are encouraged to contact Lippert at 574.537.8900 or by email at customerservice@lci1.com.
Above from Industry Trade RV Daily Report - No opinion on my part - just information.
http://rvdailyreport.com/industry/lippert-addresses-reports-of-leaking-rv-axles/
Bill
It is my understanding that GD has since specified self-adjusting brakes on the chassis supplied for their products, which should help. Lippert claims to have changed their packing and assembly processes. On the GD forum, an increasing number of new owners are insisting that their selling dealers disassemble, inspect, and service the bearings, grease seals, and brakes as part of the PDI process before delivery. In general, Grand Design is known for very good customer service and is working with owners who have "greased brake" problems after the sale. I think it's shameful, though, that Lippert should imply that part of the problem is "owner education" and post-sale service procedures when it's clear that the majority of the units with problems come from the Lippert factory that way. Perhaps I'm too steeped in the teachings of Dr. W. Edwards Deming (the man who "wrote the book" on quality management), but - even though the stated overall failure rates are low - brakes are just too important to accept any significant degree of failure.
I have written extensively in other threads (mostly on the GD forum) about the circumstances that lead us to spend the money for the MOR/ryde independent suspension. It is no secret that I am not a Lippert "fan boy." That said, I will admit that LCI has treated us very well (in concert with Grand Design) related to some furniture warranty issues. I just wish they (Lippert) would bite the bullet and make the necessary changes to keep this dangerous brake situation from occurring.
Rob