2016/2017 Greyhawk/Redhawk Recall

[Bduck100]

Here's a photo of the the unit after I took it off.

[t18skyguy]

Originally Posted by jd99336

Just to clarify....3/16 is heavier than 2/16 (1/8)...or am I missing your intention? Maybe 1/4 versus 1/8? Thanks.

JD you got it right. I got mixed up in the brain.

[t18skyguy]

Originally Posted by Bduck100

Here's a picture of the broken support bracket. Broke just above the gussett.

Wow, the the tensile strength of 3/8 steel is over 4000 pounds, but when you look at that picture, you see that divot right in the middle? It looks like it is right at the top of the gusset. I see some rust, but am wondering if it's a cold weld at the top that started that crack. I was going to weld two gussets both sides. Maybe I should just go with Jayco's bracket, but I have a big trip coming up and they can't get the bracket till after. I asked, and they won't let me install it cause it's a NHTSA recall and I'm a licensed mechanic. I think I'll try to rig up some temporary support in case it breaks so it doesn't hit the highway. Sorry or what happened to you Bduck.

[gprapim]

Originally Posted by jd99336

Mine is at the dealer right now and I am concerned about the competence of their repair. I am considering going and getting it and taking it to my son-in-law who has a well equipped welding shop.



Your photo, however has created a question in my mind that I hope someone can clarify. My set up looks roughly the same, except the piece of channel that holds the pump fits flush to the rail of the chassis and they tack welded the channel to the chassis rail (at the factory).



The photo appears to show the channel extending well below the frame rail. Is that correct, or is it just a camera angle thing???

Here is how I fixed mine. It hangs down also. I did this two years ago when I noticed the potential problem, long before Jayco did their recall. Not so pretty welding, but very effective fix. It is from the frame to the upper part of the bracket, taking the whole load off of their L set-up.

[jd99336]

Just spent some time looking at these photo's with my son-in-law who does steel fabrication and welding work (tig, mig and stick). When he looked at the pic with the arm extended below the frame his initial reaction was something along the lines of "what brilliant engineer thought this was a good idea". He explained that while steel is strong, it does not handle flexing well over time and get's brittle. I this case, that is why they were breaking at or near the weld. The Jayco gusset fix adds nothing because the added piece is not welded where it offers any support to the arm that the pump is suspended on...just adds more weight.

In my case, the channel is flush with the bottom of the frame rail. He pointed out that this reduces the stress on the original weld area, but still is not ideal. He said that in his experience, welding to the truck frame rails is not allowed after the original manufacturer....at least on commercial trucks (he doesn't know on motorhomes.

When I get this back from the dealership service department, I want to see what they actually do as the gusset will likely not fit and with the level of professionalism I have seen at my dealer, they will either do nothing or they will screw something up. After this is all done, I think I will have him fabricate a system that offers better support (he has a plasma table for making AR 500 targets, so should be able to come up with something) then weld it up. It will be impossible to avoid welding to the frame, but not sure what else to do.

[Bullitt6283]

Originally Posted by jd99336

....Your photo, however has created a question in my mind that I hope someone can clarify. My set up looks roughly the same, except the piece of channel that holds the pump fits flush to the rail of the chassis and they tack welded the channel to the chassis rail (at the factory)......

That's how mine is. I sent this photo to Jayco and they said no repair is needed.
.

[jd99336]

Methinks I will be fetching my Greyhawk from the dealer tomorrow lest they screw something up

[Tyeee]

I posted a couple of pictures on the "Class C Motorhome" Thread titled TSB #19-022 Leveling Jack Hydraulic Pump Mount Bracket Reinforcement. They may give you an idea what the new bracket looks like.

[Click_here]

Had our 2017 Greyhawk in for some minor, end of warranty repairs and they also found we needed the recall leveling jacks fix. Surprisingly, done in record time too.

[Jim_in_WA]

So got the notification off the forum about the recall. Called Jayco and was told my rig was not effected (or is affected), fine, cool. This morning, drive my rig onto the driveway and snap! See pics. Contacted Jayco again and now told it will be covered. Problem is, Campingworld, Savannah, can't get me into until 22 Oct and more than likely won't be fixed until November. Sorry that won't do. Got a mechanical engineer friend that answered my call on FB for recommendations. Taking it to his shop to get new braces made and welded into place. Gotta love it.







Attached is the bracket piece which broke as I drove into my friends shop driveway. Luckily had it supported by three ratchet straps. Again my friend who is a mechanical engineer and welder looked at the part and pointed out the dark areas on either side of the break are indicative of too much heat used during the OEM weld. This heat penetrated the metal causing a weak point at the end point of the weld. This is exactly where the part failed. The bracket he fabricated is MUCH MORE SUBSTANTIAL. I will post a series of pictures detailing what that bracket looks like today as soon as I can get under the rig and snap some good ones. BTW total time to fix: 3.5 hours including two beers. Next avail appointment to have the recall item "looked at" at Savannah Camping world: 22 Oct. LOL.






Here you go as promised. Pics of upgraded bracket.

[Bullitt6283]

It looks like the bracket failures are related to the LCI (Lippert) levelling system, which has a physically larger pumping unit and must have the bracket which hangs down lower.

My Greyhawk has a 'Equalizer Systems' leveling system, which enables the horizontal part of the bracket to be welded directly to the frame.
.

[K9Nardu]

My dealer finally received the latest updated repair parts from Jayco to perform my Greyhawk recall on 3-16. I will post some pics when completed.

[K9Nardu]

Had the recall performed today by my dealer with the latest version of the repair bracket/hardware supplied by Jayco (this is Jayco's third design attempt). Fantastic design and a really nice job done by the dealer! The repair has the dealer completely cut the old support bracket off the frame, and a new bracket is bolted on in its place. A really nice heavy duty bracket with an ingenious design. It appears that it should hold up well, and I am very pleased. It was raining when I arrived home after the repair. I will post some pics tomorrow.

[K9Nardu]

Here are the pics of Jayco's latest recall bracket design for Greyhawks and Redhawks. Looks pretty good to me. Very beefy. Stock bracket was ground off by the dealer and this was bolted on in its place.