AL-KO Rear Suspension Torsion Bar FAILED

Ed on Toast

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Well, Well

It would seem that my rear suspension torsion bar has failed.

Anyone had this happen and or know the best route to rectification?

All advice most welcome. I heard some places will recondition it for you, anyone know about this? recommend?
 
It may be worth PMing Tom (stonedaddy) i think he changed one last year.
I hope you sort it out easily.
 
Well, Well

It would seem that my rear suspension torsion bar has failed.

Anyone had this happen and or know the best route to rectification?

All advice most welcome. I heard some places will recondition it for you, anyone know about this? recommend?

Have a word with Tom (stonedaddy) he had the same thing happen to his Burstner and he is in your area
 
Well, Well

It would seem that my rear suspension torsion bar has failed.

Anyone had this happen and or know the best route to rectification?

All advice most welcome. I heard some places will recondition it for you, anyone know about this? recommend?

I take back my offer, I don't want to swap anymore :dance::dance::dance:
 
Try fraserbrown engineering co.uk
They specialised in alko they did mine great service
 
This happened to a friends van on the way to Spain, so they had it replaced with a new one, but don't know the details of how.
 
Well, a bit of internet access so time for an update on the Al-Ko

I took things easy, took a deep breath and took me and the camper up to Nigg, in the Highlands of Scotland to (thanks everyone) Fraser Brown Engineering.

They lifted the back end, dropped off the axle and opened it up to expose the torsion bars.

To say they had failed was an understatement, but why?

Quite simply because Al-Ko have put the grease nipples in the wrong place and so grease does not find its way to the inner surface of the bearings, where it is needed.

I was 'umming' and 'arrring' about getting the chassis fully reconditioned or just buying a second hand one and putting that on. So, so glad i opted for the fully reconditioned path.

I am taking loads of pictures, but alas the internet in the Highlands is not the fastest, so they might need to follow.

I arrived Thursday and should be off on the road again by Tuesday morning but in that time the axle has been removed and is now in the process of total reconditioning.

Whole Torsion bar from drivers side end.jpgClose up of Torsion  bars Drivers side.jpg


Fraser and Sue, his wife, together with Jim and Dougal, from the workshop and Tim (drafted in to help) have all been and continue to be fantastic. It is now Saturday evening and we are more than half way through, finishing off Monday.

There work is to the very highest standards, while it is being done, I am jacked up on blocks at the front of the workshop, as Fraser and Sue's guest, no charge and with EHU.

Some work, such as the cleaning off of the main axle is out sourced to a local company, so Fraser took me along, so I can see the whole process. I am also able to walk about the workshop, following each part and taking as many pictures as I like.

Fraser has axles couriered here from all over the UK and so he takes pictures, so the customer can see the state of things before, during and after reconditioning.

If this was not enough and trust me with this fantastic scenic view, it should be but Fraser and Sue insist on me taking supper with them each evening and tonight, for example, he is smoking (his home smoker, a hobby) some cheese, so I can sample it, with a glass or two of port (well i supplied the port, lol)

To think I may have opted for a second hand Al-Ko axle from a scrappers, which could, of course been equally damaged, as it only really shows under load ! ! ! or it could have failed tomorrow ! ! !

But thanks to great advice from my Wild Camping community, I opted for a trip to Fraser Brown Engineering, where I am confident of the highest standards of workmanship and customer service.

Fraser pointed out that the original grease nipples are actually inaccessible with the fresh water and waste water tanks fitted, so his team will remote them to an accessible point.

I am now confident that a Fraser Brown Engineering reconditioned axle will last longer than the original!

"Never in the field of campervaning, has a breakdown been such a thoroughly enjoyable experience"
Winston the Wanderer 19:45
 
Well, a bit of internet access so time for an update on the Al-Ko

I took things easy, took a deep breath and took me and the camper up to Nigg, in the Highlands of Scotland to (thanks everyone) Fraser Brown Engineering.

They lifted the back end, dropped off the axle and opened it up to expose the torsion bars.

To say they had failed was an understatement, but why?

Quite simply because Al-Ko have put the grease nipples in the wrong place and so grease does not find its way to the inner surface of the bearings, where it is needed.

I was 'umming' and 'arrring' about getting the chassis fully reconditioned or just buying a second hand one and putting that on. So, so glad i opted for the fully reconditioned path.

I am taking loads of pictures, but alas the internet in the Highlands is not the fastest, so they might need to follow.

I arrived Thursday and should be off on the road again by Tuesday morning but in that time the axle has been removed and is now in the process of total reconditioning.

View attachment 54305View attachment 54306


Fraser and Sue, his wife, together with Jim and Dougal, from the workshop and Tim (drafted in to help) have all been and continue to be fantastic. It is now Saturday evening and we are more than half way through, finishing off Monday.

There work is to the very highest standards, while it is being done, I am jacked up on blocks at the front of the workshop, as Fraser and Sue's guest, no charge and with EHU.

Some work, such as the cleaning off of the main axle is out sourced to a local company, so Fraser took me along, so I can see the whole process. I am also able to walk about the workshop, following each part and taking as many pictures as I like.

Fraser has axles couriered here from all over the UK and so he takes pictures, so the customer can see the state of things before, during and after reconditioning.

If this was not enough and trust me with this fantastic scenic view, it should be but Fraser and Sue insist on me taking supper with them each evening and tonight, for example, he is smoking (his home smoker, a hobby) some cheese, so I can sample it, with a glass or two of port (well i supplied the port, lol)

To think I may have opted for a second hand Al-Ko axle from a scrappers, which could, of course been equally damaged, as it only really shows under load ! ! ! or it could have failed tomorrow ! ! !

But thanks to great advice from my Wild Camping community, I opted for a trip to Fraser Brown Engineering, where I am confident of the highest standards of workmanship and customer service.

Fraser pointed out that the original grease nipples are actually inaccessible with the fresh water and waste water tanks fitted, so his team will remote them to an accessible point.

I am now confident that a Fraser Brown Engineering reconditioned axle will last longer than the original!

"Never in the field of campervaning, has a breakdown been such a thoroughly enjoyable experience"
Winston the Wanderer 19:45



How very refreshing that someone actually posts gratitude of work being or has been getting carried out .looking forward to final update ,good on all them up there .
 
Might be worth a look here Ed;

https://www.wildcamping.co.uk/forum...ase-/8511-alko-torsion-bar-expert-needed.html

I must admit, I haven't read it all through, but you may get some information.

I had to have an entire new axle. Cost over £2.5k I think. I was under the impression though that the newer ones like I now have have individual bars in them that can be replaced unlike my old one but I Cant remember. I drove mine around for ages with it knackered though, all the way back from the south of France and then all round Devon and Cornwall.
 
Thanks for the update Ed,some useful information there.Quite surprising that the grease nipples for the axle are inaccessible when the water tanks are fitted,what a poor design.Little wonder it has failed with no lubrication for such a long time,I have mine greased every year at service time as recommended by alko.
 
Thanks for the update Ed,some useful information there.Quite surprising that the grease nipples for the axle are inaccessible when the water tanks are fitted,what a poor design.Little wonder it has failed with no lubrication for such a long time,I have mine greased every year at service time as recommended by alko.



Quite simply because Al-Ko have put the grease nipples in the wrong place and so grease does not find its way to the inner surface of the bearings, where it is needed.


If yours is the same it doesn't matter how much grease is pumped in if it doesn't get to where it is needed. Maybe you should check.
 
Quite simply because Al-Ko have put the grease nipples in the wrong place and so grease does not find its way to the inner surface of the bearings, where it is needed.


If yours is the same it doesn't matter how much grease is pumped in if it doesn't get to where it is needed. Maybe you should check.

I'm not sure about this,initially Ed said that the cause of failure was due to Al-Ko putting the grease nipples in the wrong place and so the bearing wasn't being greased properly,if at all.He then goes on to say that the positioning of the water tanks by the converter made the grease nipples impossible to access.It's not clear whether the design fault by Al-Ko with incorrect grease nipple positioning or the converters daft positioning of the water tanks thereby making them impossible to reach and so lack of lubrication is the cause of the axle failure.

Al-Ko recommend greasing the axle once a year with the load taking off the axle i.e. with the axle hanging from the chassis and both wheels off the floor.
 
I think it is a little bit of both, Steve.

Al-Ko put the nipples in the wrong place to get the grease to the correct place internally and then Weinsberg totally masked the nipples behind the fresh and grey water tanks.

Fraser Brown Engineering remove the original nipples and re position new ones (remove 2 replace with 4, btw. One for the centre of each of the four bearings. They then machine a groove in the centre of the bearing to allow the grease into the correct place and finally remote the nipples to an accessible point on the camper.
 
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just have to set up reminder to to the greasing now wellweird was only thinking yesterday morning that we had not heard from you and was hopefully thinking that your van wasbeing sorted good news it is
 
just have to set up reminder to to the greasing now wellweird was only thinking yesterday morning that we had not heard from you and was hopefully thinking that your van wasbeing sorted good news it is

Indeed. Going now am I. Coat I will get.

Cheers:cheers:

Yoda
 
The repairer sound great, glad to hear you'll be sorted soon.

Cheers.
 
different than mine

Ah I now see that your torsion bars are totally different than the ones I changed on my shed, so my info was of no use to you but who knows someone else may find it useful. May I ask the year of your Motorhome?
 

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