Listing / wobbly Thule powered single step 460

[avmac]

So our new to us Carthago CL138 had a wobbly Thule single 12v step when we bought it. We asked the dealer to address it at the time but we were told 'there was nothing to fix'. It's become worse and is listing when retracted or extended and is clunky when moving. Stepping down onto it it there is significant play which doesn't instil confidence.

Having reviewed the Thule step threads on MHF I've been under the van to check for a cracked side frame. I can't see any cracks in situ but there's road cack and an extra deflector plate in the way.

However, disconcertingly there is almost a bend in the top section of the side frame that butts up underneath to bolt onto the motorhome (non motor side). So instead of sitting flush there is a gap so that I can get my fingers in-between. There is also a distinct clunk/slop at the non-motor side pivot near the footplate so there may also be a worn bush.

I've looked at Hillview Awnings which does spare step parts. Before we get into taking it off to inspect it more thoroughly can anyone advise how to tell whether this is the standard or short variant step? Are references to LH side assemblies taken when looking at the MH or when looking down at the step when getting out?

Many thanks in advance for any comments or suggestions.

 

[Lenny HB]

The bend in the frame looks like the problem. Looks like easily cured with a couple more bolts.
Also check the black L bracket the step is bolted to, they have a habit of cracking along the bend on Carthago's.

 

[avmac]

Many thanks again Lenny HB - will check the bracket too.

 

[Gellyneck]

Looking at your photos it appears the step bracket is cracked \ broken at the retaining bolt.

We had a similar issue however it was the angle in the bracket that was cracked.

Think you will see from this photo where the crack is in yours, at the hole drilled for the retaining bolt head \ washer.

Whilst our bracket could have been repaired (eg additional welded angle) we bit the bullet and just replaced. Sourced from Hill View Awnings at that time (May 2018).

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Having said that Lenny could be correct in that additional bolts may work for yourself but you'll need to check access to the nut end \ reinforcing at the new positions.

 

[avmac]

Hi Gellyneck, Many thanks. I was anticipating seeing a crack at the right angle bend of the bracket. However it 'appears' to be the horizontal mounting section that has deformed and gapped away from the undersurface. It could be as a result of a crack where you suggest or elsewhere, which I just haven't confirmed it yet. Will get back underneath and try to get further photos / video after work tomorrow. I expect I'll need to demount the step to really suss what is going on. I appreciate seeing the photo of a failed side frame.

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[Gellyneck]

Hi Gellyneck, Many thanks. I was anticipating seeing a crack at the right angle bend of the bracket. However it 'appears' to be the horizontal mounting section that has deformed and gapped away from the undersurface. It could be as a result of a crack where you suggest or elsewhere, which I just haven't confirmed it yet. Will get back underneath and try to get further photos / video after work tomorrow. I expect I'll need to demount the step to really suss what is going on. I appreciate seeing the photo of a failed side frame.

Rather than removing the whole step you may be able to get away with just removing the "damaged" side as there is some flexibility. I did.

 

[avmac]

Well now that we've had time to get underneath again and investigate thoroughly, Gellyneck is correct. The non-motor side bracket has cracked towards its outer edge i.e. near outermost retaining bolt. So we thought we'd take the step off, there are only 4 bolts retaining it in total and 4 electrical connectors - should be easy we thought…

Wrong. The bolts for the motor-side bracket, especially the one closest to the footplate is rotating so the nut cannot be loosened So we dismantle the internal step of the MH to investigate and see if the other end can be accessed to get a grip.

4 Torx, 2 Philips removed, to remove the plastic internal step, following by levering off a Velcoed supporting block and we find the offending domed coach bolts. It appears that whenever the fitter tightened them, they've been overtightened and have pulled into the wood surface. Also the outmost bolts have their heads partially underneath an aluminium track and another wooden block that supports the mossie blind. Of course one of the 2 Philips heads retaining the track has been 'chewed' by previous folk accessing the area and isn't going to come out without a fight.

It doesn't look that there is enough bolt head exposed to drill down its centre. At the moment we're thinking about trying to drill off-centre to put a screw through the head into wood to stop it rotating. That's assuming the drill bit didn't slip and was even possible.

The nut won't now tighten on the bolt. So the side that had been secure isn't. We're meant to be going any next Friday. We can manage without the step but we don't want any insecure one!

Does anyone have any other - preferably better - suggestions please?

 

[avmac]

'…any' next Friday should read away - predictive text.

Thanks in advance.

 

[avmac]

First photo is the partially accessible dome head. Second is the accessible one that has not pulled into wood surface.

At least I've now cleaned all the grot that was underneath the internal step - so at least some benefit…

 

[Gellyneck]

Sorry to hear of your problems.
As a temporary solution assuming the step is retracted and can be tied up remove the dedicated fuse in the Sargent panel and buy a cheap folding step to replace
That's what we did until I got time to fix it.

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[avmac]

Unfortunately it's not retracted as we had easier access with it extended. The bracket is now loose and not sure tying up would be sufficiently secure other than for the MH staying on the drive.
Many thanks for the helpful thoughts and support.

 

[avmac]

Phew, we're back to having a secure and retracted step. Managed to place and tighten a screw into the wood so its head overlapped the domed bolt head sufficient to get the bolt to stop turning. That enabled the nut underneath to be retightened. We'd hoped we'd be able to undo the other nuts to get the step off after all. However on the cracked bracket side, someone had used overside nylon washers which have deformed and now mean a socket won't fit snugly. The metal deflector plate is of course held in place by the same bracket and bolts so there's no space for a ring spanner.

For now a simple separate step will do while we consider other step removal approaches.

 

[Gellyneck]

Phew, we're back to having a secure and retracted step. Managed to place and tighten a screw into the wood so its head overlapped the domed bolt head sufficient to get the bolt to stop turning. That enabled the nut underneath to be retightened. We'd hoped we'd be able to undo the other nuts to get the step off after all. However on the cracked bracket side, someone had used overside nylon washers which have deformed and now mean a socket won't fit snugly. The metal deflector plate is of course held in place by the same bracket and bolts so there's no space for a ring spanner.

For now a simple separate step will do while we consider other step removal approaches.

Pleased your sorted, well sort of!

We've got a folding step from Aldi (discontinued) that we carry around with us so other half can see into the overhead lockers!
Broken Link Removed

Something similar may work for yourselves.

 

[avmac]

To complete this thread, having managed with a simple fold up step as suggested by others, we've now finally sorted the Thule step. It required purchase of a nut remover to be able to remove the offending old step. On inspection both brackets had cracks with one having been 'patched' by a previous owner. So we ordered a new one and this Sunday afternoon we installed it. It's good to have a secure, non-wobbly step ahead of an upcoming longer trip.

Working parts from the old step (e.g.12V motor) will be offered free under the classifieds plus there are new electrical parts not required from the new step if anyone wants to make a small donation to their local Air Ambulance.

 

[Jimbohorlicks]

I would still use an understood support,to firm up the step and prolong its life,even a fold up plastic understep would do the trick.
Good to see you finally got it sorted ,so much for the dealer saying it was ok.

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[avmac]

Photos of cracks including 'patched' crack in mounting brackets...

 

[avmac]

Surplus parts taken within 5min of advert going up. Glad to be able to recycle.

 

[Gellyneck]

To complete this thread, having managed with a simple fold up step as suggested by others, we've now finally sorted the Thule step. It required purchase of a nut remover to be able to remove the offending old step. On inspection both brackets had cracks with one having been 'patched' by a previous owner. So we ordered a new one and this Sunday afternoon we installed it. It's good to have a secure, non-wobbly step ahead of an upcoming longer trip.

Working parts from the old step (e.g.12V motor) will be offered free under the classifieds plus there are new electrical parts not required from the new step if anyone wants to make a small donation to their local Air Ambulance.

Great you have come back and updated progress as a good few don't!