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Old 05-25-2011, 08:04 PM   #1
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Cracked Frame-Update

I have a 2005 Jayco Jay Flight 29bhs. The I-beam frame is spliting long ways in both directions from the welded in gussets. The gussets that are in front and behind the axles or next to the spring shackle mounts. I belive it's from the frame flexing or trying to roll over when corning. Is this a known problem,and/or is anybody else having this issue? My neighbor has a 2002 Jayco Quest 265bh 5th-wheel his frame is real bad. It's even busted out where the cross member is welded in
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Old 05-25-2011, 09:11 PM   #2
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Welcome to the Jayco Owners Forum CumminsMan! I haven't seen anyone post your problem with the I-beam frame yet. Hopefully it's an isolated incident and that's not a future concern for older Jaycos. Have you googled the splitting problem you have? I'm wondering if there is another way you can find out what to do in case you don't have any luck here.
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Old 05-26-2011, 07:30 AM   #3
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Dang!!! Made me go and crawl under my TT w/a flashlight checking for this...no problems found!!! I have a 2006 Jayflight 31 BHS, so now I'm really concerned and will be keeping a close eye on this thread!
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Old 05-26-2011, 07:51 AM   #4
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Welcome Cummins! Glad you found us.

Would love to see some pictures of the splits so we can get a better idea of the issue.



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Old 05-26-2011, 08:00 AM   #5
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Have you contacted Jayco or the frame manufacture? Often there is extended warranties on some of these parts.
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Old 05-26-2011, 08:47 AM   #6
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No problems under my 2006 Jayco 29 FBS. Then again, my "pre-owned" TT sites on a seasonal site 99% of the time. Before buying, I did lots of reasearch and looked for "problem patterns". During my research, I didn't see frame problems within the 26-32 ft TT's. Seen a few problems with their ultra lites (possibly from off-roading adventures - LOL!!!) but didn't see any problem patterns with Jayco Feather Flight class. Thus, "we bought it". re: Our Jayco Feather Flight class...

If it broke once, it will probably break again (if fixed with same parts). To fix "better then factory", I'd take to a few welding shops. And, get them to fix better then factory. re: Replacing I-Beams with thicker / better I-Beams and/or sistering supports down the existing I-Beams. This is how I'd fix it. re: Better then factory build.

Good luck....
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Old 05-26-2011, 09:31 AM   #7
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Smile

My 2008 31BHDS looks fine and we have several thousand miles on it going over steep mountain passes with lots of corners and turns with no signs of stress or cracks. Hopefully it is just an isolated case, Keep us posted on how you fix it.
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Old 05-26-2011, 10:24 AM   #8
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Quote:
Originally Posted by kfbeaver View Post
My 2008 31BHDS looks fine and we have several thousand miles on it going over steep mountain passes with lots of corners and turns with no signs of stress or cracks. Hopefully it is just an isolated case, Keep us posted on how you fix it.
I guess I could have also mentioned that we've gone about 10,000 miles with our tt so far. Ours is ok still too
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Old 05-26-2011, 04:40 PM   #9
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I contacted Jayco today. Waiting on a call back. When I get home from camping this weekend I'll take some pic's of my neighbers his cracks are 5 to 6 inches long. Mine r only about 3/4 of an inch long. Then I'll see if I can upload them on here.
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Old 05-26-2011, 04:54 PM   #10
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I believe many of Jayco`s frames are made by Leland engineering and have a good record overall compared to some of the others. Not sure which one made the frames in question. I do hope they will help with the repairs. Some of the earlier liteweight frames had some issues as well, but the 29BHS is not a liteweight.
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Old 05-27-2011, 07:33 AM   #11
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Cracked Frame Pictures

I heard from Jayco today. Their comment (Its 4 yrs out of warrenty) Would not say one way or the other if there is a problem. Just said they have a good ratio. They did say they use Dexter frames and axles. So i have a call into them.
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DSCN0944.jpg   DSCN0945.jpg   DSCN0946.jpg   DSCN0947.jpg   DSCN0948.jpg  

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Old 05-27-2011, 08:04 AM   #12
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Nice pictures. I now have a visual of your original post.

Being "out of warranty", I'd take to a few welding shops in your area. A certified & experienced welder can inspect those cracks and advise how they were made. For example, too much chassis stress, too much upper weight, too hard of bumps, lifting the TT from its ends without center support jacks, etc. etc. And while inspecting, they can also recommend methods of fixing it. For example, sistering supports down each side of the I-beam. And, perhaps adding more gussets.

Thanks for providing pictures.

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Old 05-27-2011, 08:21 AM   #13
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Looks like those cracks are over the suspension, midship, too much flexing in the frame fore and aft. Frame too weak for the load ? trailer loaded too heavy ?? too many rough roads?? things too consider.

Just welding up those cracks, they will come back. Weld on plates on the cracks, and the crack could move to the edges of the new plates?

Maybe remove suspension, hangar brackets and what not, and run a heavy tube under the frame to spread the stress, fore and aft of the suspension a couple of feet maybe three feet. It would raise your trailer whatever size of tubing you put in there. Kind of like double framing. Reweld new hangars and suspension components.

Did one many years ago on a triple axle, he was having the same problems on a custom trailer.
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Old 05-27-2011, 05:35 PM   #14
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cummins man,

I so sorry you are having to deal with this. This should not happen to a quality product. I'll bet lots of us would like to know how this turns out for you. Please keep us informed as to how Jayco and Dexter treat you, and what repairs you undertake.
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Old 05-28-2011, 08:26 AM   #15
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I would consider contacting the HTSB..let them look at it and decide if this is normal and safe..
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Old 05-28-2011, 02:04 PM   #16
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I crawled under my 308FBS and everything looks good. I add 2 stab jacks about midway a few years ago to stop all the flex while camping. Maybe that has stopped the problem.
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Old 05-30-2011, 06:26 PM   #17
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Had a great holiday weekend camping. Stopped at the Jayco dealer on the way Friday to get an est. for a new roof. He looked at the frame and said he won't be to worryed about it. Just so u all know the last two pictures with the little cracks are my trailer. Big cracks are the neighbers trailer. Must not be thinking but what does HTSB stand for? I'll let u all know what Dexter as to say when I hear from them.
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Old 05-30-2011, 06:44 PM   #18
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I crawled under my 308FBS and everything looks good. I add 2 stab jacks about midway a few years ago to stop all the flex while camping. Maybe that has stopped the problem.
My long TT's have middle scissor jacks (or support axle stands on the frame) as well. And, no cracks under my TT's frame either. Perhaps you are onto a positive pattern...
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Old 06-05-2011, 12:11 PM   #19
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Cracked Frame Update

Heard from Dexter Chassie. They are aware of the issue. Their fix is to weld a piece of C-channel or U-channel on the bottom of frame rail,from frame to frame,or side to side. At the front and rear spring shackles. This is to stiffen the frame. Problem is the frame rail trying to roll when corning.
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Old 06-05-2011, 06:12 PM   #20
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Good information to know. Did they say they would fix it for you......free?

May want to ask the moderator to move this update to your original thread, other folks following the original thread may miss the update.

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