Recently I was driving my 2003 Newmar Dutch Star diesel pusher across barren west Texas when suddently the rear suspension lost it's air and settled on the frame. The unit is built on a Spartan Chassis and has 50,000 miles on it. When the coach settled, the spinning drive shaft came into contact with the frame and created an enormous vibration and noise. I didn't know what had happened but I eased over to the shoulder and got out to do a visual inspection. I thought maybe a rear tire had blown, but they were all OK. There was a roadside rest area just ahead so I drove the coach there and parked. I put down my jacks and raised the coach so I could crawl under the rig and I immediately found the problem. An "L" shaped metal bracket used to attach the suspension control valve rod to the frame had broken and the rod was dangling freely, thus opening the air ride control valve and allowing the air to escape and the coach to sink. I called Good Sam Roadside Assistance and they dispatched a repairman. He was located over 130 miles away so we waited for about three hours for him to show up. He did a temporary fix and we drove the coach home with no further problems.
After I got home I removed the broken bracket and discovered why it had failed. The bracket is made of 1/8 inch steel that is one inch wide with 2 1/4 inch legs. Two 1/4 inch holes were drilled in the leg that attached to the frame. However, only one bolt was used to attach it and it was placed in the hole nearest the end of the leg. This method allowed to much flexibility and after time, the bracket failed at its weakest point, across the unused hole.
I urge everyone riding on a Spartan Chassis to inspect your rig and fix this before it becomes a problem. I was very lucky in that the driveshaft, transmission nor the rear differental were damaged, but very easily could have been. Also when the suspension was lost, it became very difficult to control the coach.
Don't let a two dollar part cause major damage to your rig. Personally, I made a bracket out of 1/4 inch steel and bolted it on with two bolts. If I didn't explain this situation clearly, call me at 254-876-2693 and mabye I can do a better job over the phone.
Butch Walker
After I got home I removed the broken bracket and discovered why it had failed. The bracket is made of 1/8 inch steel that is one inch wide with 2 1/4 inch legs. Two 1/4 inch holes were drilled in the leg that attached to the frame. However, only one bolt was used to attach it and it was placed in the hole nearest the end of the leg. This method allowed to much flexibility and after time, the bracket failed at its weakest point, across the unused hole.
I urge everyone riding on a Spartan Chassis to inspect your rig and fix this before it becomes a problem. I was very lucky in that the driveshaft, transmission nor the rear differental were damaged, but very easily could have been. Also when the suspension was lost, it became very difficult to control the coach.
Don't let a two dollar part cause major damage to your rig. Personally, I made a bracket out of 1/4 inch steel and bolted it on with two bolts. If I didn't explain this situation clearly, call me at 254-876-2693 and mabye I can do a better job over the phone.
Butch Walker
:approve: :approve: