Leaking Lippert Axle Seals

[otrfun]

I seem to remember reading a post or two about the seals on some Lippert axles being problematic. Searched but couldn't find anything.

FWIW, the brakes on our 5th wheel toy hauler (with 7k Lippert axles and 12x2 Axletek brakes) have been less than stellar since we took delivery. Took our TH to the dealer a few months ago and they said the brakes were functioning properly. With our warranty ending in a few months figured I'd pull the drums just to play it safe. Glad I did. All four axle seals had varying amounts of grease leaking around them. One was leaking particularly bad with a thick layer of grease all over the brake shoes.

Seems strange that all four were leaking. Did Lippert have a large batch of bad seals? Or, did Lippert use the EZ/Super lube zerk fittings during assembly and force-in too much grease. I never grease these zerk fittings just because of the risk of blowing grease past the seals. IMO, annual repacks should be sufficient.

Fortunately, our dealer was willing to submit a warranty request to Lippert based on pictures I took of the brakes, seals, and drums.

Still thinking seriously about doing a disc brake conversion. At least with disc brakes the axle seal is clearly visible so any leaks can be caught early 🙂

[otrfun]

I decided to call Lippert Customer Service about their warranty repair policy in terms of leaking seals.

The gentleman I spoke to in the chassis and axle dept. (who personally approves warranty claims), said they typically approve the replacement of the entire braking backing plate assembly when seals contaminate any part of the braking assembly. Obviously the labor to clean this stuff up would easily surpass the price of a new one.

He also said if they receive photographic evidence of excessive brake drum scoring they will also approve brake drum replacement, too. Of course, this only applies to warranty situations involving faulty axle seals. They obviously don't warranty normal wear and tear.

This is encouraging to hear. Got this gentleman's name and number just in case.

[drsteve]

otrfun wrote:
Anyhow, the dealer doesn't have the capability to turn drums.

Most auto parts stores should be able to turn those drums.

[mbopp]

If you can find a local brake and clutch shop or truck repair place they should be able to turn the 2 surfaces on the drums.

[otrfun]

Lynnmor wrote:
Grease did not cause the abnormal wear on the drums. I believe that you are talking about where the magnets meet the armature face and, if that is the case, your new magnets will be damaged by the old drums.

What happens with new shoes or greased brake lining, the operator turns up the controller and makes the magnet work too hard just to get some braking. It's all downhill from there.

Appreciate the reply. Actually, the armature face on each drum appear to be in good to excellent condition---flat with no obvious scoring that I can see. It's possible the grease may have helped in that regard--lol!

However, the part of the drum that contacts the brake shoes is scored quite a bit. I suppose wear-is-wear. Would be nice if there was something to look for that differentiates "normal" wear from wear aggravated by grease contamination.

[otrfun]

Second Chance wrote:
No, Lippert does not use Zerk or "easy lube" fittings on these axles . . .

Here's a pic of one of the Lippert 7k axles on our TH. Does Grand Design use a different type of Lippert 7k axle on their units?

[Lynnmor]

Grease did not cause the abnormal wear on the drums. I believe that you are talking about where the magnets meet the armature face and, if that is the case, your new magnets will be damaged by the old drums.

What happens with new shoes or greased brake lining, the operator turns up the controller and makes the magnet work too hard just to get some braking. It's all downhill from there.

[Second_Chance]

mbopp wrote:
There's a lot of chatter over on the Grand Design owners forum about leaking seals on Lippert axles. The problem seems to be more on the heavier axles, the 3500# ones don't have as many complaints.

mbopp is correct about the chatter on the Grand Design forum. No, Lippert does not use Zerk or "easy lube" fittings on these axles. The problem is in the assembly process with overpacking and contamination... probably aided and abetted by low-quality seals and/or hasty assembly. Lippert claims to have put the process changes in place to fix the problem by this past November, but buyers are still taking delivery of rigs with the issue in mid to late December. The only remedy is to disassemble, clean and inspect each hub/bearing/brake assembly, replace any contaminated brake components, repack the bearings properly, and replace the seals with good ones. Grand Design has been doing this under warranty for owners (and likely charging it back to Lippert, I'm sure).

Rob

[otrfun]

Dougrainer, fj12ryder, and mbopp, thanks for the replies. Dougrainer, especially appreciate all your behind the scenes insight!

Well, I just got a call from the service rep at our local dealer. He said Lippert approved new seals and backing plate brake assemblies for all four wheels. That's the good news.

Bad news is the brake drums are also scored and worn unevenly from all the grease. The brake shoes are like new in terms of thickness---as they should be, since they've been well lubricated--lol! Anyhow, the dealer doesn't have the capability to turn drums. I guess they replace them vs. turning them. Lippert did not approve any action on the brake drums other than cleaning.

We'll see how it goes. The dealer's pulling for me, but ultimately it's Lippert's call. If Lippert says I need to foot the bill for the brake drums ($400-$500) due to it being a "wear" item, well . . . I just may ask them to put it together with just new seals, new backing plates, and old drums . . . and put the $400-$500 towards some new Kodiak disc brakes ($1500 for everything at etrailer.com). Got to put safety first.

I may have some "like new", 12x2 backing plate brake assemblies for sale next week. Stay tuned.

[mbopp]

There's a lot of chatter over on the Grand Design owners forum about leaking seals on Lippert axles. The problem seems to be more on the heavier axles, the 3500# ones don't have as many complaints.

[dougrainer]

We sell a warranty Forever on ALL new vehicles. This requires that the Trailer seals MUST be checked every year to keep the warranty in force. We have found that LCI does a LOUSY job of
1. packing the bearings correctly
2. Using low temp bearing grease
3. AND if you have the bearing buddy system, THAT will cause the grease to bulge out the seals IF NOT greased correctly for the Bearing Buddy system.
So, yes, there is a problem with LCI Axle systems. If you have one, make sure you pull them down that first year and repack with hi temp grease and install new seals. LCI may warranty, but it is a pain to jump thru the hoops to get LCI to warranty these type issues. Doug

[fj12ryder]

IMO a lot of the problems like this arise from damaged sealing surfaces. I've checked my brakes/hubs and was amazed at how poorly the units must have been handled to do the kind of damage I saw. Nicks and gouges were common on surfaces that need to be smooth to enable a seal to do its job. Very poor condition.