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Old 02-22-2015, 11:23 AM   #1
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2013 Freightliner Maxum Chassis cross member cracked

I have a 2013 Winnebago 42u with a Freightliner Maxum chassis. I was walking through my bedroom to my rear bath & I could hear something under the coach that sounded like there was something loose & hitting on to something underneath, with the coach leveled on jacks & slides out. So I went under the rear area behind the tag axle & had my brother move around in the bedroom area. What I found was the chassis cross member above the tag axle oil canning. So I bumped it with my fist & the sheetmetal filler between the upper & lower cross member beam popped forward, which in turn stopped the oil canning sounds. So upon further inspection I found that several of the spotwelds that held this panel on to the beams to form the cross member had cracked & pulled away from the beams.

Freightliner has a 5 year warranty on the frame & cross members. So I took the coach into San Diego Freightliner last week & had them inspect & decide what needed to be done to repair this. They in turn contacted Freightliner & discussed this with them. The repair is going to be complete replacement of the cross member. Unfortunately the part/parts are on back order & expected to take up to 2 months to get it & repair. I thought this was just a filler panel, however Freightliner seemed very concerned & I was told it is a pretty important panel. The good news here is that it is going to be repaired correctly & we previously planned to be in the San Diego area at least until June.

I have many years experience in aircraft structures & auto restorations.had this not been under warranty, I was thinking of adding a doubler over the damaged area & welding it on to strengthen the panel & stop the cracking.

So I was wondering if anyone else has had a similar experience? Also if you have a strange sound under your coach you should do a little investigating to see just what it is.
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Old 02-22-2015, 12:35 PM   #2
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Interesting. Got pictures to share?
Thinking others with this chassis should inspect for dame issue.
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Old 02-23-2015, 08:41 AM   #3
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I do but but you can't tell where the cracks are from the pics. Very hard to get in there & take pics. But it is easy to see if you crawl under the coach behind the tag axle and in front of the engine /transmission and look for the wide cross member that is just behind/above the cross member & fwd of the transmission. Make sure your coach has chocks under the wheels & the brake is set. Be careful .
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Old 04-25-2015, 06:16 AM   #4
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Update to spot weld cracks.

It turns out this cross member panel is a Winnebago installed part & is called a secondary floor support. Freightliner Of San Diego did an excellent job at getting in touch with Winnebago & getting approval to make the needed repairs under the Winnebago warranty. They had my motor home for a week & when I dropped it off we left for NC & they kept me informed by phone of the progress. It was 3 days before they actually got in touch with Winnebago & I feared they would not have this ready when returned from our trip East. However I received a voice mail while we were flying back to San Diego that the motor home was ready for us to pick it up.

I inspected the work & they actually added about 12" of weld to the edges, top & bottom of panel & also rewelded the spot welds, painted the area & all is well. The panel is much stiffer now that it has been repaired.
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2013 Winnebago Journey 42e, 2014 Featherlite Car Hauler 3110 17.5', 2008 Mazda MX5,
2008 Toyota FJ Cruiser
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