Steamdrivenandy, cabbie37 - I'm starting to come to that conclusion myself, given the feedback I've received so far, that the problem was caused at the previous service and the nut was cross-threaded when replaced then. The problem is proving that this was the case but, given the overwhelming feedback so far, the balance of probability is becoming quite clear. The question is, will the service centre accept this? I guess I'll soon find out - the complaint email is WIP...

Some interesting stuff here....

https://www.caravantalk.co.uk/community/...p-axle-problem/

Someone had the same problem. Comments include Alko going to the dealers to sort, and having to return to base with the axle as the hub to axle bolt has a torque of 700Nm and specialist gear needed to tighten and set up camber angles etc. (this would explain why the axle would need to go back to Alko - but not necessarily be replaced).
also an anecdote (may be true) regarding a service engineer using the wrong nut which in turn got jammed.
Unfortunately no info on who finally paid the bill.

The axle repair presumably would be something akin to my recent axle upgrade where the axle was removed from the van, both hubs withdrawn and refitted with uprated rubbers. I assume (reasonably?) that that is specialised work that only Alko are set up to carry out. Though I also recal (was it) Fraser Brown Engineering could also carry out this work. Though clearly, a new hub assembly is going to be needed...

Thanks Steve - this seems very relevant. Regardless of who paid (it does say that the caravan was still in warranty) the inference is that the service tech would have been responsible.

Sorry to hear of your troubles ExRex.

If you have caravan insurance or RAC/AA membership maybe they could answer the question. I would have thought an experienced technician would have used a nut splitter then run a thread die up the stud to clean the thread, which after working in my father's garage from a young age. Is a much safer way not to course damage. Still have my set of nut splitters and die set, pullers and many other invaluable tools and so on.

Still best advice is to seek how you stand, like I say above, seems from what you explained, as negligence to me from reading your post.

Phillip.

I wonder where the dividing line between negligence and incompetence lies?

Is this "Erwin Hymer Travelworld" the one in Stafford?

There's little to add to what has already been said but In my opinion what you describe is butchery of the first degree. At the first sign of it tightening the nut should have been removed by alternative means, using a nut splitter or carefully cutting the nut off would be my approach.

Perhaps you could get the remains of the stub axle and nut checked by a competent mechanic who would be willing to challenge the standard of the work done on your behalf?

Best wishes with this,
Steve.

It sounds like you have had a terrible experience, I cannot offer any technical advice but one thing is for sure a lot of folks on this forum will give that establishment a wide birth.

A quick update - I have submitted a formal complaint about the serivce I recieved during my Eriba's service and that the additonal charge (and justification for it) cannot be based on any environmental or "wear and tear" effects. I have used many examples you have provided in order to illustrate my rationalle so (again) thank you for all the input you have provided.

The Customer Care Manager has referred this to the Service Centre Manager for "investigation". I'll let you all know what their response is once I receive it.

A further update for those interested - I received a phone call from the service centre Customer Care Manager yesterday afternoon. She said that the person who had sent the original email to me had misunderstood the situation and that my axle would be sent to a local machine shop to have the stub axle threads "machined" at their cost. So, looks like my letter of complaint worked but I am still somewhat dubious about the circumstnaces behind all this and the suggested resolution - she reassured me that my caravan would be returned to me in a sfae and roadworthy condition.

Has anyone here had any experiecne of machining / re-threading stub axles? I my experiecne, any rethreading, regardless of whether it's just a light dressing of the threads, would involve metal off and so reduce the overall diameter of the stub axle......

I would tend to agree. The threads are shagged (technical term) and can't be re-instated by any engineering process I am aware of (Neil Grafo may wish to comment) As you suggest, the only real option would be to reduce the diameter of the stub axle, machining off the damaged thread and then cutting a new thread on that which, as you rightly point out, is now a smaller diameter. You could perhaps add a tight fitting 'tube' loctited and pinned in place that the original thread could be cut on to, I suppose? But I would have concerns that would threaten the structural integrity of the piece.

I would get (in writing) a very clear description of the process they intend to follow and an assurance that some sort of guarantee will be supplied afterwards.

Possible wrong end of the stick alert, but depending on exactly how your axle is constructed, page 186 et seq of this catalogue seems to suggest that replacements parts might be available? Perhaps JohnE may be able to comment on that..

https://www.alko-tech.com/sites/default/..._04-2018_en.pdf

Had a quick word with Neil, he rarely comes on here. His thoughts: if the thread has been totally stripped then the only way that he is aware of would be to machine the shaft to remove all the thread and recut a new thread on the reduced diameter shaft. This will obviously alter the thread size of the nut ( too large an internal diameter) and would require another nut which the machine shop may well make/find. The nut will require some sort of locking mechanism ie a Nyloc which shouldn’t be reused so may cause an issue for future servicing, an odd size nut being needed every time. Having said that provided they can source a nut the integrity of the axle shouldn’t be compromised. However they have admitted liability and you should really be put back in the position you were in originally so you want a new axle.