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KiwiAngler

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Reply with quote  #1 
As some of you may have read on an earlier post I am in Melbourne currently getting work done on my 490.

The initial problems with:
1) The wear on the wheel hubs and brake pads and magnet and
2) The back and forth movement of the wheel drop/swing arms.
3) The Hitchmaster DO35 ver1 has worn
These were all initially noted by my mechanic at Wagga when I put it in for a brake pad check and bearing repack.

Knowing my mechanic couldn't do the trouble shooting and then the repairs I contacted Mark at Tough Touring in Morrabbin, Victoria (note Mark is a member of this forum)

After speaking with Mark about the issues I decided to drive from wagga to Melbourne so Mark could see the issues first hand.

From the moment I arrived Mark and his team have done everything possible to get the issues diagnosed and repaired - I cannot say enough about them at this point.

First the Alko wheel hubs

Remember I have done close to 300,000kms over the last 8 years and a large proportion of that has been over serious off road tracks- in other words - my 490 has been well tested.!!

The hubs have signs of wear and probably require skimming so I've decided, on Marks advice, to replace the Alko hubs with xxxxxxxx (I will edit this later once I find where/who they are coming from) as they are more robust and Mark believes I will get better life from them - these have been ordered and are on way, due to arrive Monday and should be a simple task to swap out the old and install the new.

Next the Drop/swing arm assembly

Once the camper was put up on blocks the springs were removed and both swing arm assembly were removed.

One arm was ok and the shafts that run through the assembly moved freely

The other was completely seized within the drop arm body itself and must have been like this for sometime ( I did go through a stage where the camper squeaked excessively when the body was rocked but put it down to having just spent a month on dirt roads with a lot of bulldust - I sprayed the drop arm assembly with water and WD40 and the squeak went away - perhaps on reflection all I did was mask the real issue)

Because the shaft was so seized the drop arm shaft itself has worn a flat spot and where it goes through the hole in the hanger on the chassis it has flogged the round hole into an oval - this is where I'm getting the movement first noted by my Wagga mechanic.

It has taken Mark a few hours, using a sledge hammer at one stage, to free up the seized shaft enough to extract it from the swing arm body.

I've just left Tough Touring and Mark has sent the shaft to a nearby engineering firm to make up 2 new shafts, which will be made a bit stronger than the original shafts are.

The plan is to have all hub/wheel assembly parts together with the new shafts etc by Monday with a Tuesday install and get me back on the road by Wednesday

I've got my fingers, toes and eyes all crossed that this happens

Pic shows:

Flogged out hole on hanger

Seized shaft in drop arm assembly






Attached Images
jpeg 20180523_130048.jpg (504.40 KB, 78 views)
jpeg 20180523_125546.jpg (631.04 KB, 76 views)

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William the Conqueror

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Reply with quote  #2 
Hi T

Wonder if that "flogging out" is caused because the shaft has been machined to small for the hole?

Might have to add dropping the Swing Arms and checking and greasing the shaft to my annual strip down! Although mine (actually nobodies) gets a hiding like yours does. If I get to 300 000ks and that's all that needs replacing id be happy.

Good to see Mark picking up the level of service for the Brand - others needs to follow his lead.

Cheers

Anthony

PS also sent you a PM

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KiwiAngler

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Reply with quote  #3 
WTC

Definitely agree about a regular checking of swing arm although you have to have knowledge and equipment that allows you to remove the springs as they are under tension

I think Conqueror SA should look at this side of the suspension as it is not well designed in my opinion.

Perhaps bearings either end of the shaft and the ability to get grease into the enclosed shaft without having to drop the arms ?


And while they are at it- a better way of adjusting the wheel alignment ?

Mark of Tough Touring is definitely getting some knowledge on this side of a Conqueror after all the time and effort he is putting in on sorting my current issues 🤤

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Garry H

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Reply with quote  #4 

interesting stuff, my 490 is also 8 years old, although has only done ( ?? ) Km's, I'm not the original owner, mine still has the original tyres on the rims and show distinct wear on the inside, I've reversed the tyres on the rims and rotated the spare to get a little more life from them in the mean time

I've also been thru the "squeeky" stage when the body rocks and rolls, I to, possibly have only masked a much bigger problem

I certainly would welcome a replacement shaft setup where I could actually get some grease into it

Looks like a black top road trip to Melbourne to visit Mark is on the cards before to much longer

Garry

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KiwiAngler

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Reply with quote  #5 
Garry
I'm due to get back on the road again on Wednesday so will have a better idea of costs and how well the new set up is going - Mark and his team have definitely learnt a lot by doing my repair - especially as the shaft was well and truly jammed up .

You sound as though you have the same symptoms as mine exhibited. I would not let it go on for much longer as it will make the job of repairing a lot harder.

Definitely reckon it would be worth the trip down to let Mark check if out.
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Marksills

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Reply with quote  #6 

Hi Guys !
Some news on the 'seizure' - and what to look for (Pre 2013 440 and 490 trailers). 
Don't Panic ! - Bear in Mind that Kiwi Anglers trailer has done a LOT of Kms. Testament to the endurance of the design. 

The "A Arm" moves on a large through axle which is through bolted with nylock nuts each end. This is the area you want to inspect. You won't be able to tell if there is any movement in the A'Arm unless the A'Arm is completely unloaded. To Do this we removed the wheels, Coil springs, and Sway Bar. 


On inspection - under the Nyloc Nuts on the inside mount - there is a large steel retaining washer/ plate, followed by a eccentric aligning 'washer' of sorts that allows the arm to be wheel aligned. 
Its a robust design - but its failing is in its difficulty in servicing. 

To Service:
Remove Nyloc Nuts each end - Position a Jack under the A Arm and tension so that the A'arm through axle is no longer carrying the vehicles load. 
Gently try to 'tap' the through axle  through the chassis mounting points. It should spin freely in there and with a light tap start to slip out for inspection. 

If this happens - All good ! - The axle actually spins on large Plastic Bushes inside the A Arm - Tap out around 6 inches, Clean - then Lubricate with Superpro nylon / Silicone Grease Or similar. (Not regular  grease). Tap the through axle back through until it protrudes 6 Inches from the other side and Repeat the process of cleaning and greasing. - Put it all back where it was and bolt it all up again. Entire process takes about 2 hours. 

If it doesn't move / spin or you can't get it out - and its seized - The through axle will be beginning to move on the chassis mounting plate. (Steel on Steel) - This will eventually elongate the chassis mounting point and cut away the axle, while creating  'slop /wobble' and excessive movement in the A'Arm and driveline. Eventually the A'arm axle will fail.

Greasing the steel on steel will help slow down the process, but over time the grease will bake and mixed with dust turn into a cutting compound. 

If the A'Arm Pin failed at speed on a highway it would result in the A'arm and wheel coming free and probably jamming under the rear of the trailer, locking up that side... 

We are cutting a run replacement 'through axles' via local engineers to have them on hand should anyone need a replacement set. These will be hardened and we're aiming to have them designed to be adjustable for wheel alignment improvements.

The Later models of 490's have a different set up - we will investigate this also over time, 
We are not at all reliant on these parts out of Conqueror - so don't stress 😉 We'll be here a long time. Local engineers here reproduce everything we need to improve and maintain  😉 

Replacement kit will include:

*Replacement Bushes
*Replacement of existing Through axle with a Servieable High Tensile Through Axle
*All bolts and required hardware.

Servicing done here can include:
*Sandblasting and Raptor re-painting of the A'Arm (Raptoris a stone chip resistant two pack epoxy coating)
*Fitting of all components and upgrades on Axle and Brake assemblies too if required.


Cheers - Mark 
Tough Touring
Moorabbin VIC


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William the Conqueror

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Reply with quote  #7 
Thanks for the comprehensive reply Mark.

As I've said before you are stepping up to the plate in terms of after sales service. Obviously, this is of commercial interest to you however, the reply above will definitely help many owners. Hopefully others within the sales/service side will follow suit.

Cheers

Anthony

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Garry H

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Reply with quote  #8 
well done Mark !! 😉

count me in on a pair of new pins, I'd rather have them replaced than just run with whats there forever, especially knowing now what we know.

Mmmm ok, when to get to Melbourne?.. message coming your way

Garry 
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KiwiAngler

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Reply with quote  #9 
Mark

Thanks for the great work you and the guys have done on my 490.

I'm back in Wagga now and the camper felt great to tow - and for the first time in a long time, no squeaking !!😂

The new wheel hubs, which are a few inches longer axle than the old Alko ones have improved camper stability

I will be back next year for you to do the maintenance on my A arms and get them sandblasted and sprayed with the Raptor two pack epoxy coating - the sample you showed me looks very good.

The new Hitchmaster hitch is working well and this new version is easier to use than the old mark1 version I've had since new.

I'm leaving Wagga on the 5th June and heading over to Alice and will be going across the Gary Junction Road to Marble Bar so 1) I'm glad the issues with the seized and worn pins was found before I headed out and 2) the new pins will get a good workout

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jpeg 20180523_130139.jpg (494.83 KB, 8 views)

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RichardC

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Reply with quote  #10 
Great write up.
I also have just been through this with my 2008 commander and had issues with being able to get the correct bushes to fit the original A arm and pins and in the end I got a local engineer to make me new pins.
One thing I wish I had done was get them to drill the pin and tap a grease nipple into the end so the bush’s can be greesed without disassembly.
It’ll be good to know going forward that Mark will have spares on hand now and won’t have to wait for parts from OS.
Cheers Richard.
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KiwiAngler

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Reply with quote  #11 
I was in a bit of a hurry ( need to get across to Alice) when Mark had my new shafts/axles made so we didn't have time to put in a grease nipple but it's something we discussed and will probably be included in the production ones Mark will be making.

I was also lucky in that I had 4 of the green plastic type bushes (new, unused) already so didn't have the issues of having to make new ones - I've left 2 of the original bushes with Mark to use as templates for the new ones to be made.
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AlexL

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Reply with quote  #12 
Hi guys,
Do you guys have a part number for SuperPro or Nolathane bushes that support the pin? My mechanic thinks I might need to replace one of mine in the A-arm.

Much appreciated,
Alex
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Marksills

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Reply with quote  #13 
We haven’t got any part number. If the bushes are flogged out - it’s most likely that the axle shafts are also going to be stuffed.
The bushes rely on the axle - and as we’re having new ones made (hopefully with greasable nipples) - we’ll have to make bushes to suit them also.
Watch this space - we’re hoping to have a kit out before Chrissy
Cheers - mark
Tough touring
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8111colin

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Reply with quote  #14 
I wrote about this exact problem 2 years ago , it happened to my companion, I had two new high tensile steel shafts made up , the weight was wearing away the thread , the new ones were made with less thread on the inside so as the weight would sit on the shafts , they made up new bushes as well and I packed the shafts with silicone grease .

My trailer had only done 20,000 kms
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Marksills

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Reply with quote  #15 
Hi All ! 
Quick Update - The design work on the corrected A Arm Axles and Bushes is complete - I can confirm that the new set up includes a total of 8 greasing points (4 nipples) on the 2 pins. Should be the end of any wear on the pins,  and squeaks will also be a thing of the past! We also sourced Nylon bushes and all components needed to swap out the old set up. 

The cutting job went on with the engineers today -  ! 
We'll have a dozen sets ready to go in a couple of weeks at worst - Anybody needing a set or an install -  please call us a couple of weeks before your need them to give us time to book in, post them out etc...  

If yours are flogged out - Dont stress (it is typical of the wear to cause the old mounting point to become elongated). [wink] - we have oversized these ones so theres room to move - The old mounting point is bored back out to perfectly round first before the new ones fit in...

Cheers guys 😉 
Mark@toughtouring.com.au
0477 002 932

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