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Old 05-01-2007, 06:40 AM   #1
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Hi folks. New to the site. It is great. Learned a lot from all 76 pages. I Had a brake fire on my 2003 W22 chassis left rear. Glad it self extinguished. Upon inspection, the brake caliper was dry and brake fluid level was normal. Axle beam was wet. Axle was overfilled. Out of the fill hole on flat level ground, I drained fluid into 4 styrfoam coffee cups and two large plastic beer containers before the fluid was level with the fill hole. In my opinion, you could not have filled the axle with this much fluid in service. It had to be when the axle was manufactured. Purchased the Tiffin Alegro Bay used and this was the first outing. ABS sensor was fried and replaced. Happy Motoring John350
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Old 05-01-2007, 06:40 AM   #2
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Hi folks. New to the site. It is great. Learned a lot from all 76 pages. I Had a brake fire on my 2003 W22 chassis left rear. Glad it self extinguished. Upon inspection, the brake caliper was dry and brake fluid level was normal. Axle beam was wet. Axle was overfilled. Out of the fill hole on flat level ground, I drained fluid into 4 styrfoam coffee cups and two large plastic beer containers before the fluid was level with the fill hole. In my opinion, you could not have filled the axle with this much fluid in service. It had to be when the axle was manufactured. Purchased the Tiffin Alegro Bay used and this was the first outing. ABS sensor was fried and replaced. Happy Motoring John350
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Old 05-01-2007, 12:33 PM   #3
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John350, welcome to irv2 and the Workhorse forum.
Thanks for the info hope your all set now.
Enjoy the forum and do post often.
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Old 05-01-2007, 01:29 PM   #4
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<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by John350:
Out of the fill hole on flat level ground, I drained fluid into 4 Styrofoam coffee cups and two large plastic beer containers before the fluid was level with the fill hole. In my opinion, you could not have filled the axle with this much fluid in service. </div></BLOCKQUOTE>John350, You should be good to go! Looks like someone at Dana got a little exuberant with the differential fluid at the time of assembly. I believe that the differentials come already filled and mounted on the assembly line.

It's not likely someone would overfill an axle housing on the assembly line at WCC.
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Old 05-01-2007, 11:48 PM   #5
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John350, welcome to iRV2.com. Great to have you join us. Sorry to hear of the brake fire but glad to hear that no one was hurt and that the fluid level in the rear axle has been corrected. Looking forward to reading of your adventures and experiences. Enjoy the website. Good luck and take care.
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Old 05-02-2007, 03:44 AM   #6
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I agree with you driver. It was most likely overfilled at the time of manufacture and not at Workhorse. Just a follow up, since I was in Florida at the Sebring 12hr race, I had all kinds of mechanical advice. After a few brews, some good some bad. Sprayed everything with brake clean. Drove the MH back up north to Michigan with no known leakage. The wheel speed sensor was a simple DIY replacement. You must drive the coach around 25mph to reset the computer ABS.

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Old 05-02-2007, 06:37 PM   #7
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I understand massive overfilling can cause foaming and loss of cooling to the bearings but unclear on how some overfilling hurts. I always have overfilled my 4wheeler axle to insure adequate oil to wheel bearings. I know its a semifloating rear axle and the W-22 is a full floating. BTW, been doing that for about 30 years on same 4wheeler.
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