Ouch a broken spring.

Just to close the loop on my comment on this post about wanting to upgrade springs on our 4 year old TT:

Since springs are only part of the problem, this morning I closed the deal on swapping our 3,500 lb Lippert axles for 5,000 lb Dexters. Finally found a non-RV shop 40 miles away that actually does this routinely and seems to know what they are doing. As part of the deal this guy keeps your old suspension/tires/wheels so the price was about 65% of what I expected. Plus, I already had budget approval to replace our 5 year old tires this spring anyway.

Our trip weight is 7,550 with 1,000 lbs tongue weight, so we are typically 400 lbs away from suspension (and braking) limits. This trailer only had 700 lbs of payload capacity when we bought it new. (Yeah, I didn't know to look at this when we were shopping).

The trailer guy crawled under it this morning and came out shaking his head, said the springs were flat and the axles were almost bowed in the opposite direction (and it was 400 lbs under trip weight this morning). He said, as we all know, that newer TT's come grossly under-axled and run right at the breaking point.

Parts will be here in 2 weeks and I'm excited! (I'm easily entertained). I have been weighing everything that goes in the trailer and run a spread sheet that calculates all the weights versus design limits. Worrying about breaking a spring or bending an axle has really sucked some of the enjoyment out of our longer trips.

DW gets extra credit for patience on her housewares weight budget. I told her today to go ahead and order that hot tub and I'll find a place to mount it on the trailer.

I wish I had done this a couple of years ago!

At this point it appears there was more damage than first met the eye. This insurance company and the RV dealer are working out the details.

In regards to an earlier post question, the spring broke where it met the lower spring. It was a clean break, I suppose the lower spring provided a bending point.

We will see how it all works out.

Just remember, installing upgraded springs does not increase your trailers weight rating. You can't carry more load just because you increased the springs. For that reason, the load on the axles will not change as a result of a spring upgrade.

When my spring broke I contacted Lippert and they took care of new springs on the one axle but would only replace with the same springs as original. They said they were not allowed to install heavier springs even if I paid for it. I have 4,400 pound axles so the original springs were 2,200 pound. My "on the road" trailer weight is 7,800 pounds. I was 1,000 pounds under spring capacity anyway. When I got home I replaced all four springs with 2,500 pound springs. Now I'm 2,200 pounds under the spring capacity. A little more margin of error.

At the same time I installed a wet bolt kit. Between them and the springs I really improved the handling of the trailer. Not to mention the peace of mind from springs with more reserve and spring shackles with some real strength and stability.

I am wondering if stronger springs will increase the chance of bending the axles? I have found a 2,000 and a 2,100 lb spring that will fit in place of my 1750 lb springs with no modifications.

These axles are not famous for being over-designed. It seems like stronger springs would increase the force on the axle when going over a bump, since the springs will resist the bounce more.

Anyone had a problem with bending an axle after (and because of) replacing springs with a stronger spring?

No problems with higher rated leaf springs bending a axle tube...however make sure the new springs are the correct length for that axle design and spring hanger locations and your not planning on carrying more load.
I assume you did a 1-800 to your axle maker for their recommendations on your upgrades.
I've replaced higher rated spring packs on my equipment trailers at the suggestion of Dexter axles/Rockwell American axles. These trailers were usually run in the 200k-300k miles ranges before they were taken out of service.

BONUS QUESTION: My current springs are 4 leaf, but the 2 stronger springs mentioned are 3 leaf. Does going from 4 to 3 leaf cause any problems?

Not as far as the axle tube itself goes.
However the springs still have to be the same loaded and unloaded lengths as I mentioned above.

I am very interested in replacing my springs with the next load range up because I have some sagging on one side. Mine is double 3,500 lb axles.

I am wondering if stronger springs will increase the chance of bending the axles? I have found a 2,000 and a 2,100 lb spring that will fit in place of my 1750 lb springs with no modifications.

These axles are not famous for being over-designed. It seems like stronger springs would increase the force on the axle when going over a bump, since the springs will resist the bounce more.

Anyone had a problem with bending an axle after (and because of) replacing springs with a stronger spring?

BONUS QUESTION: My current springs are 4 leaf, but the 2 stronger springs mentioned are 3 leaf. Does going from 4 to 3 leaf cause any problems?

I hope i solved the broken spring problem for good. New trailer has the Torflex rubber suspension.

I have bought springs at a farm supply store, they had them in stock. Any competent garage can do the repair. There is no need to find an RV mechanic.

The hardest part of changing a spring is getting a new one sent in. When I broke one returning from CO last year a mobile tech and I just replaced both springs on the axle in about and hour and a half at an RV park. I could have done it myself but it was under warranty and Lippert took care of the cost. I would think it would be easiest to have it repaired and then just tow it home. Your situation may dictate otherwise and only you can make that decision.

I can't see the picture so I guess I really don't know the extent of the damage.

According to the CAT scales I have about 5600 lbs. on the TT axels and 750 lbs. on the tongue.

The dent in the rim is a mystery but I think I should have felt a jar for something that hard. Perhaps not.

As it stands now, the problem is getting it towed home. My insurance company paid to have it towed to a local dealer/repair facility for an estimate. But that is 120 mile south of me and I if I want it done locally I have to pay for the tow home.

The tow home is excess of $1300.00 so I guess it gets repaired where it is.

At least it is reasonably close to home and it is the slow season.