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Old 07-21-2009, 05:40 PM   #1
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Disc Brake Pad Disintegrates On '06

As some of you know I had a brake line fail (spring a leak) on our trip down to Morris Meadows last year (http://www.airforums.com/forums/f439...end-45278.html). Well a year and two months later the excitement was on the way home from the same campground. On the trip back home the road side front outside disk brake pad on the trailer disintegrated. The trailer braked just fine on the way home and I did not notice it until I was leveling the trailer and chalking the wheels in the driveway. I noticed that the road side front brake rotor looked “funny,” it was all scored up, not shinny like the other three. So I jacked the trailer up and pulled the wheel to find the outside brake pad had disintegrated and the baking plate for the brake pad had been rubbing on the rotor. So basically the brake pads, rotor and the brake calipers are ruined!!! I called Airstream to see if there was anything they could do even though the trailer is out of warranty. They recommended that I try Dexter. So I am going to call Dexter tomorrow to try and get them to cover it under warranty. But if they don’t it will cost me all but $900.00 in parts to fix it. Luckily I can fix it myself and will not have to pay the exorbitant labor rate at an RV dealer.

Here are some pictures of the mess. The inside brake pad shows normal wear and still has 5/16" of pad material.
You can see the scoring on the rotor from the brake pad backing plate rubbing on the rotor.
The rubber boots on the caliper are shot.
What was left of the brake pad found in one of the caliper cups.
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Old 07-21-2009, 07:28 PM   #2
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Read your previous post last year, here we go again. Glad no serious consequences


The last time I cruised the Colonial website I noticed some of the 09's & 10 are back to drums. Wonder if there is something they ain't tell'n us. When AS first started using disc's I thought of the upgrade, maybe holding off for awhile was the right thing, wait and see.

Good luck and "STREAM SAFE"...sic.
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Old 07-21-2009, 07:32 PM   #3
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Quote:
Originally Posted by ROBERT CROSS View Post
Read your previous post last year, here we go again. Glad no serious consequences


The last time I cruised the Colonial website I noticed some of the 09's & 10 are back to drums. Wonder if there is something they ain't tell'n us. When AS first started using disc's I thought of the upgrade, maybe holding off for awhile was the right thing, wait and see.

Good luck and "STREAM SAFE"...sic.
Also glad no serious damage.

They may be back to drums since actibrake is no longer.
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Old 07-21-2009, 09:12 PM   #4
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Also glad no serious damage.

They may be back to drums since actibrake is no longer.
I read a post to a thread here that they were switching to the hydraulic brake pump actuator from Dexter.

I guess one of these two...

Dexter Axle - Trailer Axles and Running Gear Components - K71-650-00 E/H1000 (Drum Brakes)

Dexter Axle - Trailer Axles and Running Gear Components - K71-651-00 E/H1600 (Disc Brakes)
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Old 07-22-2009, 12:18 AM   #5
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Hi, without everything right in front of me to see with my own eyes, I would say that you have a caliper slide problem; Symtems, One pad shot other side/pad, OK. Where ever the pads and or calipers slide they need to be lubed with Brake lube or Anti-seize. You can reseal the caliper [new boots] and replace the pads and rotor. I would pull all of the brakes and lube all points of movement with Anti-seize. More than likely not covered by warranty, but it wouldn't hurt to try.
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Old 07-22-2009, 04:43 AM   #6
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ROBERTSUNRUS - Our 07 Classic has fixed calipers. Not sure whether the 06 had
floating calipers.

John in the UK
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Old 07-22-2009, 06:02 AM   #7
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Our '06 has fixed calipers. I will see if I can rebuild the calipers. Thanks for the information.
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Old 07-22-2009, 08:24 AM   #8
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Bob is correct in his diagnosis: I had the same pad problem with an LTD Ford,which had set on the docks in Brm GER for a month, while waiting shipment. The inner pad slide slot had rusted from salt water exposure. After pick-up in SC ,and the drive to Tn; the inside pad/caliper/rotor were destroyed.woppa4
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Old 07-22-2009, 12:56 PM   #9
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Thumbs up Bit Of Good News From Dexter

I just got off the phone with Connie at Dexter Axles. They were very nice and cooperative. Since they only offer a 2-year warranty the agreed to sell me the parts that I need at 1/2 of retail. I also found out that they have a caliper rebuild kit so I wouldn’t have to purchase an entire caliper assembly (the most expensive part of the lot).

So the prices came to;

Caliper rebuild kit - $15.60
New rotor - $77.59
8 brake pads to do both axles $179.34

Total - $272.53 - Which is quite a bit shy of my original estimate of $889.11 so I am happy.

Once I get the parts I will post notes and picture of the rebuild and assembly.

Hopefully this will be the last of my brake issues on this trailer.
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Old 07-22-2009, 01:52 PM   #10
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? is the rotor so damaged that an auto/brake shop couldn't turn or resurface the rotor. woppa4
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Old 07-22-2009, 04:28 PM   #11
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Bob's got it right! It appears that you have a floating caliper that automatically centers itself on the rotor. A fixed caliper has pistons on BOTH sides of the rotor, a floating caliper has pistons only one ONE side. When you burn through one pad prematurely, that means that the caliper hangs up and makes one pad do all the work. For your kit, you need only replace the outer dust boots and save yourself some work. Check your other calipers for an incipient problem too.
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Old 07-22-2009, 05:49 PM   #12
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Quote:
Originally Posted by woppa 4 View Post
? is the rotor so damaged that an auto/brake shop couldn't turn or resurface the rotor. woppa4
Wopa 4,
It's pretty messed up. I will take it to a shop to see if it can be turned, but I would just as soon have a new one.

Quote:
Originally Posted by Excella CM View Post
Bob's got it right! It appears that you have a floating caliper that automatically centers itself on the rotor. A fixed caliper has pistons on BOTH sides of the rotor, a floating caliper has pistons only one ONE side. When you burn through one pad prematurely, that means that the caliper hangs up and makes one pad do all the work. For your kit, you need only replace the outer dust boots and save yourself some work. Check your other calipers for an incipient problem too.
Excella CM,
From your description I definitely have fixed caliper brakes, because there are a total of four pistons; two on each side of the rotor.
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Old 07-22-2009, 06:01 PM   #13
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Necessity Is The Mother Of Invention

Since I am going to be able to rebuild my calipers I was chomping at the bit to get the pistons out of the bores and clean everything. So when I got home from work I fired up the air compressor and tried to blow the pistons out into a towel. Well it worked great for one of the two pistons on each side of the caliper which left one remaining in each side...how to get that second one out???? After pondering on it for the better half of an hour it finally struck me...The bores looked about the same size as the rubber plugs I use to plug up the return jets in our pool when I winterize it. I dug one out and sure enough it fit like a glove. I tightened the wing nut which causes the plug to expand and it sealed perfect. I applied some air pressure and POP the remaining pistons was expelled from their bores. Now all I have to do is wait for the replacement parts to arrive some time early next week.

Here are some pictures of the solution to the problem...
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Old 07-22-2009, 08:16 PM   #14
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You still need to identify the cause of the lopsided braking effort. This could either be a problem with pressure distribution (unlikely) or the pad hanging-up. Or something else.
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