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Old 02-05-2008, 03:36 AM   #1
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Per the information on installing the grease fitting(Zerk), I drilled a hole in the center of the brake relay rob, and found that the center rod goes all the way through, per the install information "there isn't a full length shaft in the tube". I have a 2004 32' Tiffin Allegro. I realize that if the grease fitting extends through the brake relay rod and binds the center shaft, not only will no grease come out of the grease fitting, but the brake system will not work. Any thoughts??????????????

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Old 02-05-2008, 03:36 AM   #2
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Per the information on installing the grease fitting(Zerk), I drilled a hole in the center of the brake relay rob, and found that the center rod goes all the way through, per the install information "there isn't a full length shaft in the tube". I have a 2004 32' Tiffin Allegro. I realize that if the grease fitting extends through the brake relay rod and binds the center shaft, not only will no grease come out of the grease fitting, but the brake system will not work. Any thoughts??????????????

Johnnie
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Old 02-05-2008, 06:28 AM   #3
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K1, that was my experience too. 2004 W20 Bago.. I had to start the drill hole, then grind a flat point on the drill bit, finish the hole. Then do the same with the tap, start it, then flatten the end, and continue the "tap"..all this so as NOT to drill into the inner shaft. I got very few threads in there, but carefully installing the zerk it holds. I'll be gentle on it tho.. Something of a chore to do, but it does lube all the way to the top and bottom..Wasted a couple of tools, but my 55+ yr old tool box has plenty of spares.. BTW, before and after, my linkage always released "all the way"...rgr...
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Old 02-05-2008, 10:00 AM   #4
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<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">per the install information "there isn't a full length shaft in the tube". </div></BLOCKQUOTE>
k1hog: please advise where you read the above. thanks, ed
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Old 02-05-2008, 10:23 AM   #5
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edgray, the information was obtained from this forum, with pictures!

Why?

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Old 02-05-2008, 11:01 AM   #6
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<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Why? </div></BLOCKQUOTE>
Because I'd like to correct the mis-information, if possible, since it is obviously wrong. Can you provide a link? ED
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Old 02-05-2008, 12:09 PM   #7
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Zerk fittings have been routinely fitted to relay rods for a number of years by simply drilling, tapping and securing the fitting. Grease will work its way to the top and bottom of the relay rod and the required lubrication will be correctly applied.

I have not ever read where it has been an issue on anyone's part regarding binding or any other type of anomaly that would prevent the normal operation of the relay rod.

Use a sharp bit and recover the shavings as they are removed from the material by not allowing them to enter the hole in the relay rod.

Go for it!
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Old 02-05-2008, 12:13 PM   #8
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The local Workhorse service center put mine in the very bottom part of the relay rod. I suppose that will still work??
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Old 02-05-2008, 12:21 PM   #9
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Driver, did you have any problems with getting the pilot hole drilled, and hole tapped? I expected to find a cavity between the housing and shaft, but the clearance was really minimal..thus the modified drill and tap.. not what I wanted to end up with, but all I could get...rgr...
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Old 02-05-2008, 12:58 PM   #10
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<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">The local Workhorse service center put mine in the very bottom part of the relay rod. </div></BLOCKQUOTE>
HERE is where they put mine. ED
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Old 02-05-2008, 01:54 PM   #11
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Was there a recall by Workhorse for the zerk fitting on the relay rod? My 2004 W-22 does not have a fitting, I have not expierienced any binding to my knowledge.

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Old 02-05-2008, 03:40 PM   #12
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ED, did you watch them install yours?.. Thats where I put mine, but as I've posted, there is a MINIMUM amount of inner/outer clearance on mine, that made it less than a straight forward deal.I guess I anticipated a smaller, bearing supported inner shaft, much smaller OD than the outer housings ID, with ample clearance in between.. ....rgr...
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Old 02-05-2008, 03:44 PM   #13
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<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Was there a recall by Workhorse for the zerk fitting </div></BLOCKQUOTE>
I dont think its a recall, Ive understood they would do it free tho, on request. Dont KNOW that for a fact, just been told that...rgr..
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Old 02-05-2008, 03:54 PM   #14
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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 rgrstndgby:
Driver, did you have any problems with getting the pilot hole drilled, and hole tapped? I expected to find a cavity between the housing and shaft, but the clearance was really minimal..thus the modified drill and tap.. not what I wanted to end up with, but all I could get...rgr... </div></BLOCKQUOTE>rgr, My zerk was center punched, drilled and tapped. It didn't appear to be any more of an issue that that honest.

This process has been repeated numerous times and I haven't heard anyone comment that the process didn't complete as planned.

The component that redirects the input from the brake pedal to the Hydro-Max is the relay rod itself. Whatever is going on inside the relay rod is not part of what actually makes the brakes work but is a component of the relay rod. In my opinion there is nothing in there that is going to bind and or prevent the service brakes from operating by the introduction of a zerk fitting.
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