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Old 09-22-2018, 12:02 PM   #1
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Disc brake failure

[QUOTE=Dskyward;690496]Just wanted to ask around if anyone has ever experienced or heard of a catastrophic failure in any type of trailer disc brake conversion like below?

The Story:
This past Thurs evening, weíre pulling our 42í Jayco North Point 377 RLBH with <2.5 yrs/25k Kodiak disc brake miles into the second rest area of the day, entering at 15 mph, and come to a stop...and it took a good bit of pedal pressure to do it. The trailer was really pushing us. I put in drive again and press the BrakeSmart controller button and NOTHING as we go forward another 30í. I backed it up to the original stop. First, I checked the TV master cylinder, itís full. I go back to the camper and see this long fresh fluid trail and find this:
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This is the driver side front axle wheel. Notice the position of the caliper. Itís supposed to be at the 9 oíclock trailing position, not at 6. All five caliper mounting bracket studs are gone! The brake hose was ripped from the caliper now hanging in front of the axle. I searched all around for stud remnants (should be 10) but couldnít find any. I walked our entrance path back another 200 yards or so...no fresh fluid trail or stud remnants. We were very fortunate this mishap happened at a rest area. It rained on us twice during the two hours it took to figure out a bandaid solution, as the caliper was contacting/dragging the inner wheel and that would throw a hell of a spark or fire display had we not have discovered this failure and continued. I ended up finding two matching bolt and nuts(smaller) in my spare collection to attach the caliper bracket back at 9 oíclock thru two accessible holes without having to remove the rotor. I did remove the tire and found minimal gouging scratches inside the wheel. I was a completely soaked dirty greasy pig after the ordeal. Fortunately, I have my closet with me.

Before leaving, I had the DW press hard on the brake to find no more fluid coming from the dangling line. So that long trail of fluid in that parking lane was it. As you can see in the pic it really splattered the tire and wheel thoroughly. We made it 35 mi safely into Ft Wayne, awaiting for a call from a repair shop to fit us in. Everyone is booked full for weeks.

Kodiak brake kit came from ETrailer and do not come with bracket mounting studs. Itís accepted the factory axle drum brake studs are reused. Iíve 7k Lippert axles. But in this case I remember the mechanic saying they had to get longer studs, so Iím not sure whoís really at fault, that this was an unfortunate happen stance.

I welcome all replies if anyone has seen/heard this stud failure happen.
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2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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Old 09-22-2018, 12:40 PM   #2
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I researched for months before buying my kits. First I've heard of it.

You're right to wonder about the installer installing longer bolts. Did he use the wrong grade? The wrong torque? Forgot to torque them? Bolts only break if they are of the wrong grade and/or tightness for the application. I'd definitely be concerned about the other caliper brackets!

Earl
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Old 09-22-2018, 12:44 PM   #3
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Disc brake failure

Yes indeed Earl, thanks on that. Itís out of warranty with them obviously. I asked them and they barely remember me as they donít do this specialty operation often, but other RV servicing. The ph guy said itíd be next to impossible to know what grade bolts were used and what torque applied. Iím trying to edit a picture in and having some difficulty. Edit...Ah, attached now.
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2007 Dodge Ram 3500 Laramie MC 4x2 DRW 6.7CTD, B&W Companion Slider 3405, Edge Evolution CS (deleted DPF/DOC-special tune), TireMinder TM-77, Firestone air springs, CustomFlow tailgate, Tonnosport tonneau cover, Champion 3100w genset
2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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Old 09-22-2018, 12:52 PM   #4
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Brakesmart huh? I have one of those dinosaurs too. Had it in my 93 Dodge. Never got around to installing it in my 07 Dodge. Have the P3.

Yeah getting anyone to step up and accept accountably is extremely rare.

I'd contract Kodiak and see if they have the hardware you need and replace them all and torque them with a good torque wrench to Kodiak's specs. The others could be ticking time bombs. Or could be that bracket didn't get the bolts torqued and were loose and sheard over time. You just don't know. Or they used different hardware on the bracket.


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Old 09-22-2018, 12:52 PM   #5
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Quote:
Originally Posted by Dskyward View Post
Yes indeed Earl, thanks on that. Itís out of warranty with them obviously. I asked them and they barely remember me as they donít do this specialty operation often, but other RV servicing. The ph guy said itíd be next to impossible to know what grade bolts were used and what torque applied. Iím trying to edit a picture in and having some difficulty.
How many 'longer bolts' were needed? Wouldn't they use the same length and grade bolts everywhere longer bolts were needed?
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Old 09-22-2018, 12:57 PM   #6
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Thanks Earl. I did contact Kodiak yesterday and finally the gentleman returned my call and said the factory axle studs to the drum brakes get reused, but I recalled the installer had to go with longer studs. They canít see me until Nov, so Iíve contacted Morryde Intl in Elkhart for an opening. They are Kodiak dealer and specialist. Iíll know something on Mon. Iíll certainly have them inspect the remaining studs.
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2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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Old 09-22-2018, 01:06 PM   #7
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Disc brake failure

Quote:
Originally Posted by oldmanAZ View Post
How many 'longer bolts' were needed? Wouldn't they use the same length and grade bolts everywhere longer bolts were needed?


Thanks for the reply oldmanAZ, I guess all studs were replaced...thought each axle had 5 stud bolts, but thereís 8 holes on the bracket and I recalled seeing a YT video that also needed longer studs. The facility had my rig for 3 days getting it all installed. $1700 for labor and more parts. I thought they did a remarkable job, aside from all the parts from the kit ETrailer sent me...it didnít include the Titan actuator mounting bracket, and yet other wiring items didnít meet the right lengths and stuff according to the installers. Plus ETrailer sent me the incorrect part no on the rotors. Right size, but came raw...I ordered E-coated. So there. So many parts and duties involved on a project like this and being fulltimers, well you can understand Iíve limited tools on hand.
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2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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Old 09-22-2018, 01:16 PM   #8
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Quote:
Originally Posted by Mopar_Earl View Post
Brakesmart huh? I have one of those dinosaurs too. Had it in my 93 Dodge. Never got around to installing it in my 07 Dodge. Have the P3.


Earl

I forgot to add our 07.5 dually MC 6.7 came with the Brakesmart, when we bought it used in Jan 2016. PO was towing goosenecks. After researching what I could find on the Internet (a pdf manual), I really like it. Original owners back then really raved about its technology being ahead of its time in that it made for fantastic towing of vehicles behind class A MHs/DPs. It worked off the TVs master cylinder unlike a timer, pendulum inertia type controllers and could be dialed in perfectly and the driver felt he was only stopping one vehicle.
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2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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Old 09-22-2018, 01:28 PM   #9
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I loved the brakesmart when I had it in my 93. I kept it to put into my 07 but didn't want any crap from the dealer on warranty issues so I installed a P3. Just never installed the brakesmart after my warranties expired. Just the other day I pondered installing it. Lol the P3 is ok for electric brakes. Once I get my hydraulic disk brakes installed, I will do how it performs. I hope better. If not I will install my brakesmart.

Wonder how many people will wonder what a brakesmart is?? Lol king of the world back in the day.


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Old 09-22-2018, 01:30 PM   #10
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Quote:
Originally Posted by oldmanAZ View Post
How many 'longer bolts' were needed? Wouldn't they use the same length and grade bolts everywhere longer bolts were needed?


Just discovered a photo from my archives one set of the original brake drum and mount showing 5 removed studs, which I sold on Craigslist. Click image for larger version

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These are from the Lippert 7k axles for 2017.
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2017 Jayco North Point 377RLBH w/Kodiak disc brakes/Titan actuator, Truma AquaGo Comfort, Sailun S637, home of Darin & Dana. Where the 377 has been towed since 5/27/16:
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