AXLE REBUILD for Bailey, Swift, Coachman and other European caravan

Is your caravan sitting very low? This often points to an issue with the rubber suspension elements inside the axle.

Here's a breakdown of why this happens and what you can do:

Understanding Al-Ko Independent Rubber Suspension (IRS) Axles

Al-Ko IRS axles use a system of rubber cords or rods inside the axle tube that provide the suspension and damping. The wheels are mounted on trailing arms that connect to these internal rubber elements. When load is applied, the inner arm compresses the rubber, which then returns to its original position as the load is released.

Common Problems Leading to a Low-Sitting Caravan with Al-Ko Axles:

• Degraded Rubber Elements: This is the most frequent cause. Over time, the rubber inside the axle tube can:
  • Lose elasticity and shape: This is essentially "rubber fatigue." The rubber becomes less springy and can't support the weight as effectively, leading to sagging.
  • Twist or shift: Sometimes, the rubber inserts can twist inside the axle, reducing their suspension effect.
  • Damage from prolonged stationary periods: If a caravan is left sitting for long periods (e.g., more than 4 weeks) with all its weight on the wheels, the rubber can deform permanently, as the weight is consistently bearing on one side of the internal rubber. It's recommended that the caravan be jacked up if it's going to be stationary for extended periods.
• Overloading: This is a major contributor to premature failure. If you consistently carry more weight than your caravan's maximum laden mass (MTPLM) or the axle's rated capacity, it puts excessive strain on the rubber suspension, accelerating its degradation. Al-Ko often attributes failures to overloading, and if your van is found to be over its MTPLM, a warranty claim can be denied.
• Bent Axle/Swing Arms: While less common than rubber degradation, hitting severe potholes or curbs, especially when overloaded, can bend the swing arms or even the axle itself, causing the caravan to sit lower and potentially leading to uneven tire wear.
• Age-Related Wear and Tear: Like any mechanical component, the rubber elements simply wear out over time, even with proper use.

Symptoms of Al-Ko Axle Problems:

• The caravan is sitting noticeably lower than usual: This is your primary concern.
• Wheels rubbing against the wheel arches: This is a clear indication of severe sagging.
• Uneven ride height: One side of the caravan might be lower than the other.
• Reduced suspension performance: A rougher ride, more jarring over bumps, and decreased shock absorption.
• Uneven tire wear: While not exclusive to axle problems, it can be a sign of misalignment caused by a sagging axle.
• Poor handling: The caravan might feel less stable or "snaky" while towing.

What to Do if Your Caravan is Sitting Low:

1. Stop using the caravan if it's severely low or the wheels are rubbing. Continuing to tow it in this condition can cause serious damage to tires, wheel arches, and potentially lead to accidents.
2. Check for Overloading:
   • Have your caravan weighed (both loaded and unloaded) at a weighbridge. This is crucial to determine if overloading has contributed to the issue and to avoid future problems.
   • Review your caravan's MTPLM and ensure you're not exceeding it. Distribute your load evenly inside the caravan.
3. Inspect the Axle Visually:
   • Look at the gap between the tires and the wheel arches. Is it significantly reduced?
   • Observe the swing arms. On a loaded caravan, they should ideally be approximately horizontal. If they are above horizontal or stay there regardless of load, it's a strong indicator of an issue.
   • Check for any visible damage to the axle tube or swing arms.
4. Professional Diagnosis: This is the most crucial step. A reputable caravan repair specialist will be able to:
   • Accurately diagnose the problem.
   • Confirm if the rubber elements have failed.
   • Check for any bending or damage to the axle.

Repair Options for Al-Ko Axles:

• "Re-rubbering" the Axle: This involves removing the axle rubbers from the caravan and replacing the internal rubber suspension elements. This is the most cost-effective solution rather than a full axle replacement. Vantage RV specialise in this service.
• Axle Replacement: In some cases, if the axle tube is damaged or the "re-rubbering" isn't feasible, a completely new axle assembly might be necessary. However, so far, we have managed to rebuild the existing axle, even with bent or broken trailing arms.
• Upgrading Suspension: We have developed spring suspension upgrades that transfer the weight from the rubbers to springs, which makes a huge difference in the towing ability of the caravan. It lifts the riding height significantly and absorbs the road shock through the spring, not through the rubbers. Most of the weight is also carried on the springs, which eliminated rubber fatigue when the caravan is left stationary for long periods. Read some of the reviews

Given your caravan is sitting very low, it's highly advisable to get it inspected by a qualified professional as soon as possible to prevent further damage and ensure your safety on the road.

Can we carry more weight after the spring upgrade?

The spring upgrade was never designed to increase the payload.

The original chassis remains unchanged; the chassis was designed for the payload specified on the manufacturer's vehicle plates.

The spring upgrade will reduce the pressure on the axle rubbers, allowing the chassis to absorb road impact forces more effectively than the rubbers could do on their own. This upgrade should enable the springs to support approximately half the caravan's weight, meaning that road impacts will be handled by both the springs and the rubbers together. Theoretically, this could allow the suspension system to manage a greater weight. However, it is important to note that the chassis remains unchanged and can only accommodate the original payload.

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