ALKO Shocker Failure

[goingbush]

Currently on an outback trip. Newish "off road" Caravan, a 2019 Red Centre 3200kg with 3500 Offroad suspension upgrade .

Packing up from a 4 day bush camp and noticed a shocker hanging down, Assumed missing bolt but the shocker rod had pulled out of the eye. Never seen such a thing, thought it must be a 1 in a million , no reports online about it .

Welded eye back on , lo and behold drive 70km (dirt road in rather good condition, ) and another shocker failed in the same way. Welded eye back on 2nd shock and travelled a further 250km - good so far.

problem when repairing in this way there is no stone protection for rod, (I could use motocross fork gaiters if I had them)


This van has 2 shocks per wheel, ALKO replacement shock is $230 each. I could press for warranty but I'd end up with the same useless shockers.

I cross referanced eye size and shock length with Monroe catalogue and I can get Replacement shocks ( fit Chev K10 Pickup truck) for US$20 Each plus $100 fedex for 8 shocks. vs AU$1840 for ALKO garbage.

I'm a bit worried about going across CGR now, might have to limp home with tail between legs across Nullabor.

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[V8Ian]

Just go for it, without the plan change. The worst that can happen is the rest of the dampers fail. That's not a show stopper. Enjoy the trip and replace the damage, or doubtful bits when you get home.

[p38arover]

That eye looks like it was screwed on.

[TonyC]

That eye looks like it was screwed on.

That was my thought, has it just unscrewed itself?

Tony

[goingbush]

That eye looks like it was screwed on.

Yes screwed on with a tiny pin, which I assume is supposed to lock it from unscrewing. Maybe ok in theory but some locktite might have been better. the pin is soft as I could grab the remnant with pliers and twist/ bend it . totally not fit for purpose.

Now that ive welded them the rubber will probably fail, not sure how it reacts to heat, it did ooze a bit when hot.



191209

[goingbush]

Just go for it, without the plan change. The worst that can happen is the rest of the dampers fail. That's not a show stopper. Enjoy the trip and replace the damage, or doubtful bits when you get home.

Shocker fail could be problematic, theres nothing to stop the swingarm from dropping far enough to dislodge he coil spring (my last van had chains to stop the suspension dropping that far) . And if the shocker had failed on the rear wheel the rod is free to flail about and damage the rear water tank , As least the rods were contained by a chassis crossmember on the front wheel

[Graeme]

I bet that the eye socket is stretching because the rod thread length is too short for the diameter of the rod and that the joint isn't locked solid. The pin is a very poor substitute for a welded joint.
Maybe weld the other shocks now before they let go.