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Topic: bent shock mounts (Read 1300 times) previous topic - next topic

Re: bent shock mounts

Reply #25 –
Same here Chuck. I've fully extended the airbags on my 01 on more occasions than I can count. I just recently replaced all my shocks and all my mounts were in good, square condition.
1987 Grand Villa ORED
2001 U320 4010

Not all that wander are lost... but I often am.

Re: bent shock mounts

Reply #26 –
George. Double shearing all the mounts would resolve issue, but I think it can be resolved by straightening and monitoring.  Because they are stretched up from overextending would recommend not getting your Coach airborne in the future. Monitor  your leveling (personally I think this is how this happened) Joking aside with poor rebound of worn out shocks would allow the suspension to top out with a lot of energy causing the same results. It's hard to imagine this happening but at Hiway speeds it can and does happen although non of us would want this Intentionally. Big bump in the road. I admit I overthink most of these problem and personally I would straighten and monitor. If it come back double shear the mounts, but that's a lot of work. Adding a backer to the back side of the angle may be sufficient also. On my project bronco I have limit straps. Would be another option, and another can of worms.
Scott

Re: bent shock mounts

Reply #27 –
Looking at the pictures again,it looks like the mount bent from compression not over extension,if overextention the bolt would be angled the other way,from the picture it's like he hit a big hole and that bent the mount,like I said before,fix the mounts then
worry about ride height.Agree with Brett,never heard of a Gabriel on a Foretravel.
96 U270 BUILD 4810
85 380SL
Drummonds TN.

Re: bent shock mounts

Reply #28 –
Quote from: John44 –
Looking at the pictures again,it looks like the mount bent from compression not over extension,if overextention the bolt would be angled the other way,from the picture it's like he hit a big hole and that bent the mount,like I said before,fix the mounts then
worry about ride height.Agree with Brett,never heard of a Gabriel on a Foretravel.
Over extended, really hard impact would push the mount bolt downward if the shocks were functional. Slamming over extended would also rotate the fastener this way with bad shocks no rebound all the unsprung weight dropping freely then slamming the mechanical limits of the shocks (axle,brakes, tires and carriage. Half the weight of the airbags)

Re: bent shock mounts

Reply #29 –
"you describe the exact same experience I had pulling out of my campsite.  I'm amazed that the shock itself is stronger than the shock mounts welded to the subframe.  Did your mounting bracket bend at all?"

Sorry for the late reply , all I can tell you is that the bottom mount is what broke.
Frank & Daisy
NO LONGER  "looking for the perfect Foretravel
36' or less non slide preferred."  She has been found and is ours.
2003 U320 36' non slide  Unit 6103
Cummins ISM 450
Allison 4000MH

Re: bent shock mounts

Reply #30 –
Yesterday I noticed two broken lower shock mounts on the drive axle. One broke on each side. A couple of years ago I had broken mounts on the driver side, tag and drive axles. The coach has Koni FSD shocks.  Koni replaced the two shocks on the drivers side but they did not say what caused the shock failure. Did the shock fail and then the mount broke or the other way?

We are in Kerrville, TX for a few days and looking for a shop to weld the mounts.

I looked at the post from Barry from several years ago. Foretravel added bump stops. I will need to look at what stops and size of stops are on my axle.
2003 U320 4010 - SOLD
2014 RAM 1500 Ecodiesel

Re: bent shock mounts

Reply #31 –
I looked at the rear suspension today and observed that there are no bump stops present to prevent bottoming out. I should have taken a picture but did not. The two frame rails that sit perpendicular to each other are actually touching each other when the coach is deflated.

In the post from Barry several years ago they welded what appeared to be washers in the contact space, thus keeping the shock from bottoming out. I plan to have a welder look at the coach tomorrow. I think I will have him weld something in the contact position. He said they would make a new and stronger bottom mount. My concern there is that if the bottom is stronger and the top mount breaks next time the top mount is more difficult to get at. Maybe the bump stops will prevent future breakage.  The coach went 16 years without breaking a mount, I cannot figure out why I get the breaks recently.

Comments are appreciated.

Thank you,
Ed
2003 U320 4010 - SOLD
2014 RAM 1500 Ecodiesel

Re: bent shock mounts

Reply #32 –
I looked at the rear suspension today and observed that there are no bump stops present to prevent bottoming out. I should have taken a picture but did not. The two frame rails that sit perpendicular to each other are actually touching each other when the coach is deflated.

In the post from Barry several years ago they welded what appeared to be washers in the contact space, thus keeping the shock from bottoming out. I plan to have a welder look at the coach tomorrow. I think I will have him weld something in the contact position. He said they would make a new and stronger bottom mount. My concern there is that if the bottom is stronger and the top mount breaks next time the top mount is more difficult to get at. Maybe the bump stops will prevent future breakage.  The coach went 16 years without breaking a mount, I cannot figure out why I get the breaks recently.

Comments are appreciated.

Thank you,
Ed
2003 U320 4010 - SOLD
2014 RAM 1500 Ecodiesel

Re: bent shock mounts

Reply #33 –
Ed, when you say broken shock mounts are you referring to the eyelet breaking off of the shock body or the tabs that are welded to the suspension frames broke off the frames?  In my case the "shock mounts" or brackets are securely welded to the suspension frames but the lower brackets are bent because shocks themselves limit the maximum extension of the suspension.  I'm in the process of fixing this all now and I will provide a more complete report once I'm done to wrap up this thread.  In the meantime i've attached a photo of the process.
George Mann
2002 U320 #5934
2017 Rubicon
2013 BMW GS
Waterford MI

Re: bent shock mounts

Reply #34 –
Also if you look in reply #5 you can see the "bump stop" which limit suspension compression.  My coach has these as well and as long as the shocks don't bind up in maximum compression you should not have a problem with that.  My problem was during maximum extension.
George Mann
2002 U320 #5934
2017 Rubicon
2013 BMW GS
Waterford MI

Re: bent shock mounts

Reply #35 –
As pictured in reply #5, I have no bump stops. Doesn't look like any were ever in place. The tabs for the bottom shock bolt broke. Let's see if I can attach two pictures.
2003 U320 4010 - SOLD
2014 RAM 1500 Ecodiesel

Re: bent shock mounts

Reply #36 –
I'm speechless.  Those brackets are 1/4" steel.  I can't imagine the force required to break them in that way.
George Mann
2002 U320 #5934
2017 Rubicon
2013 BMW GS
Waterford MI

Re: bent shock mounts

Reply #37 –
Ed is there any indication on which directional the failure happened? I would want to see the actual length of the collapsed shock. Im betting you will find they still have travel left when fully your suspension is at full travel up. Installing bump stops wont resolve your issue. You may find that this is from overextending or just hard working shocks. Im starting to think that they were a poor design and double shearing them would be a permanent resolution. Being single sheared every time they move there is a flexing on the tab/bolt. My coach when resting on the frame also has contact with the tires to the lower sheeting in the fender well. I recall be told Foretravel did this to make the coach more stable. I thought the 2002 had a built in clearance of the tire not to touch the sheeting.
Scott

Re: bent shock mounts

Reply #38 –
Quote from: Geodmann –
I'm speechless.  Those brackets are 1/4" steel.  I can't imagine the force required to break them in that way.
I can with thousands of flex cycles every mile. No triangulation

Re: bent shock mounts

Reply #39 –
Scott I can confirm that (my) 2002 does have clearance above the tires when the suspension is fully compressed and sitting on the "bump stops/steel washers"  and that the shocks are not fully compressed at that point.  I agree with your point about metal fatigue but that assumes that the suspension regularly droops to full extension (with force) during normal driving.  In spite of your (previous) implication that I have jumped my coach and gotten airborne... lol... I can assure you that I have never subjected it to that kind of abuse.  I'm glad that my shock mounts bent instead of breaking.  I'm not done fixing my problem or completely studying the geometry of the suspension at full extension/compression but I am well on my way (pesky day job) and I will provide a full wrap up and conclusion once it's done.
George Mann
2002 U320 #5934
2017 Rubicon
2013 BMW GS
Waterford MI

Re: bent shock mounts

Reply #40 –
Broken shock mounts is not limited to the older coaches compared to mine.  I did a thread with pictures on the front broken upper mounts on my 2014 IH.  Mine was a somewhat easy fix, had to buy two new upper shock plates and bolt them on.  The new plates were better braced then the original ones.
2014 ih45  (4th Foretravel owned)
 1997 36' U295 Sold in 2020, owned for 19 years
  U240 36' Sold to insurance company after melting in garage fire
    33' Foretravel on Dodge Chassis  Sold very long time ago
 

Re: bent shock mounts

Reply #41 –
Quote from: Geodmann –
  In spite of your (previous) implication that I have jumped my coach and gotten airborne... lol... I can assure you that I have never subjected it to that kind of abuse.  I'm glad that my shock mounts bent instead of breaking.
Well im confident that mine has become airborne, im not saying flying quietly threw the air, but I have hit potholes and road imperfections at speed causing the shocks to do there job by slowing the fall rate (rebound) then arresting the compression once on the other side. Certainly not intentional but happening all the time unless your coach is parked. Straightening your mounts is half the job. Prevention will require double shearing your attach points or weaker shocks lowering stress. Next you'll be tearing off shock ends, but the mounts wont fail. Double sheared mounts are the current automotive industry standard.
(pesky day job) They really do get in the way. Another year and a half for me.