The work that goes into a Casita axle replacement involves much more than just turning wrenches. The most critical steps won’t even get your hands dirty. When the axle on our 2008 Casita travel trailer needed replacing, we had no idea where to start and ended up learning a ton on our own. To help others in the same position, we thought we’d share everything we learned!
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Casita axle replacement… everything we learned!
Our Casita is a 2008 Spirit Deluxe (17-foot). However, this information applies to all Casitas and other fiberglass trailers of the same size. If you’ve found your way here, you probably already know the design and construction of Casita travel trailers has not changed much over the years. For that reason, this info is applicable for Casita axle replacements on older and newer campers.
We learned all this the hard way from scouring online forums, browsing various websites, and even a few phone calls. In the end, we sorted out the details for our Casita axle replacement on our own. Since replacing it… we’ve put over 2,000 miles (and counting) on the new axle!
In this post we’ll cover:
- The type of axle on a Casita.
- How to know when your Casita needs a new axle.
- Ordering a new axle.
- Getting it installed!
What kind of axle does my Casita have?
Casita travel trailers have a torsion axle, specifically a Dexter Torflex Light Duty rubber torsion suspension axle.
What is a Torsion Axle?
Torsion axles and leaf spring axles are the most common suspension axles seen on travel trailers.
A leaf spring axle consists of a straight axle attached to leaf springs with the leaf springs attached to the trailer frame. The leaf springs provide the suspension.
Leaf Spring Suspension Axle Configurations
(Springs Below)
(Springs Above)
Torsion axles use a torsion arm suspension system completely self-contained within the axle tube. The axle attaches directly to the trailer frame. The wheel spindle is attached to a torsion arm, fastened to an axle bar encased by rubber cords. As load is applied, the bar rotates. The rubber cords create a rolling resistance, which provides suspension.
This video shows perfectly how a torsion axle functions.
When is a Casita axle replacement needed?
Travel trailer owners should keep track of thier axle’s date of manufacture (likely the same year as the trailer itself), and be watchful of these warning signs.
Average Life of a Torsion Axle
Torsion axles have a service life of about 10 to 12 years. (Dexter does not warranty their torsion suspension axles beyond 10 years.) Over time the rubber cords within the axle dry out and breakdown making them stiffer. As this happens, the axle loses its ability to provide suspension for the trailer.
So, in 2020, when we purchased our 2008 Casita, the axle was 12 years old. Ugh!
Warning Signs of a Worn Out Axle
Here are some telltale warning signs of a worn-out torsion axle.
Rough Bouncing, Vibrations, and Hard Slams While Towing
As your Casita’s torsion axle wears out, it absorbs less and less of the road’s bumps and vibration. This bouncing and shaking transfers throughout the trailer and is easily seen in the side mirrors while towing. It’s not a pretty picture! If your trailer is bouncing out of control, it may be more than just a rough road.
Popped Rivets
The excessive bouncing and vibrations while towing will cause rivets to start popping in the fiberglass. NO good! We noticed three rivets popped in our trailer.
Complete disarray of the interior after towing
Travel trailer owners expect some shifting of stuff inside the trailer. However, if it looks like a wrestling match took place, you might want to take a closer look at the axle.
Broken cabinet hinges after travel
Besides total interior disarray, broken cabinet hinges are a dead ringer that your trailer doesn’t have any suspension. We noticed one broken hinge after our first trip!
Long and deep cracks in the fiberglass
This is the worst sign of all! Don’t let it get this far!!! Repairing cracks in fiberglass can be nearly impossible.
I need to replace my Axle… now what?
Step 1: Serial Number From Existing Axle
Climb under the Casita and snap a photo of the serial number on the existing axle. It may be hard to see, but it is there. It’s stamped into the steel tube. On our Casita, the serial number was on the back bumper facing side of the axle in the middle.
Step 2: Existing Axle Build Sheet
Casita exclusively installs Dexter Torflex axles on their travel trailers, and for a good reason, they’re the best at what they do. On Dexter’s website, you can easily request a copy of your existing axle’s build sheet. Visit the link below.
Fill in the information requested, including the axle serial number, and in the comments section, state: “Please provide a build sheet for the above-referenced axle.”
Dexter replied to our request within 24 hours. As an example, I included a copy of the build sheet from our old axle.
This build sheet has all the info needed to replace the axle in kind.
Step 3: Find a Local Dexter Distributor
With the build specifications for the existing axle in hand, it’s now time to find the nearest Dexter distributor.
Call or email the nearest distributor and let them know you’re interested in ordering a replacement Dexter axle.
You might be wondering, “does it have to be a Dexter axle?”
I suppose it doesn’t, but I strongly encourage going with Dexter. I only found a few other torsion axle manufacturers — none of them as reputable as Dexter. Dexter also offers a 10-year warranty, and it’s what Casita uses. That was enough reason for me.
Step 5: New Axle Build Sheet
After contacting a distributor, they’ll provide a clean NEW build sheet full of blanks for you to input your particular build specifications. The manufacturer will build the new axle exactly to match these specifications. It is of the utmost importance to guarantee all information is clear and accurate on the sheet before finalizing anything!!
Replacing Axle In-Kind (same same)
If you’re replacing your existing axle with an identical one, then use the info on the existing build sheet to fill in the blanks on the new build sheet.
When you submit the new build sheet to the distributor, I recommend sending the existing build sheet as well. Call and review the information with the distributor. Have them help compare the existing and new information to ensure everything looks correct.
Casita Axle Replacement Upgrade Specs to Consider
Since you’re replacing the axle anyway, it’s worth considering a couple of modifications to upgrade your trailer.
⇒ Axle Weight Capacity
From the factory, Casita installs an axle rated for 3,500 lbs. This is perfectly adequate for a trailer whose dry weight is around 2,500 lbs.
However, we travel with a lot of stuff, have the upgraded larger freshwater tank, and have added four heavy-duty jack stands. When replacing our Casita’s axle, I considered these factors and realized fully loaded up with a 3,500 lb rated axle, we might be close to maxing out our suspension.
For that reason, I decided to up the weight capacity to 4,000 lbs.
Please know though we would never load our trailer to that weight! Doing so could compromise the integrity of the trailer’s frame. I chose to upgrade the weight capacity to guarantee we have plenty of suspension in the axle when we’re fully loaded.
⇒ Start Angle
The start angle on a torsion axle is the angle of rotation from the axle’s center to the wheel spindle (or arm). This angle can be an up angle, neutral (0-degrees), or down angle. To replace a Casita’s axle, you only need to worry about neutral and down angles.
A torsion axle’s start angle affects the trailer’s ride height. Setting the start angle is only done when ordering an axle. It is not something that can be adjusted later.
From the factory, Casita’s stock axle is a 0-degree start angle. It provides a neutral ride height without any extra ground clearance.
Casita offers an upgraded “High Lift” axle, the same Dexter Torflex torsion axle, but with a 10-degree down start angle. This downturn start angle essentially pushes the tires down and lifts the trailer providing increased ground clearance. It also offers extra room between the tires and the wheel wells.
With Dexter’s Torflex torsion axle, it is possible to have a start angle greater than 10 degrees down. You could order an axle with a 22.5 degree, 32 degree, or 45 degree down angle. Each increment increases the distance between the center of the wheel spindle and the axle, essentially raising the trailer higher (more ground clearance).
For our Casita axle replacement, I ordered an axle with a 22.5 degree down start angle.
I was nervous about doing so because I couldn’t find any reliable advice online. Once installed, I was elated with my decision! It gave our trailer substantially more ground clearance making off-road travel less worrisome.
Our Complete New Build Sheet
(As an example and for reference I’ve included our completed new axle build sheet below.)
Before and After Axle Replacement
(10-Degree Down Start Angle + 15″ Tires)
(22.5 Degree Down Start Angle + 15″ Tires)
Cost of Casita Axle Replacement
As a point of reference, the new axle for our Casita cost $760.
Time to Manufacture New Axle
The distributor we ordered from estimated 4 to 6 weeks for delivery. Ours was ready in 4 weeks.
DIY Install or Professional Install?
When it comes to making improvements on a travel trailer, most of us are hands-on do-it-yourselfers, and why not? It’s fun and rewarding to see the fruits of your labor. However, when installing a new axle on your Casita there are some things to consider.
Before getting into that, though… Our recommendation is to get it professionally installed. The added cost is worth the peace of mind, and most shops will warranty their work. The best way to find a shop capable of doing the work is to ask the distributor you purchased the axle from for recommendations. The distributor might even have a shop to do the install for you. That’s what we did! It cost us roughly $250 to get the axle installed.
Now, if you’re still persistent on installing yourself… The most important thing is to figure out is if your existing axle is welded or bolted to the frame. The axle attaches to the frame via mounting brackets. The mounting brackets are L shaped and welded to the frame. From there, the axle is either bolted or welded to the bracket. In newer Casita’s, the axles are bolt-on, welded on older models. It’s something easily seen by just getting under your trailer and inspecting the brackets. Our axle is a bolt-on.
Welded axles only come off one way – you cut them off! It can be a delicate job requiring skilled handling of a grinder. If this is something you’re not comfortable with, it’s best to get a professional for the job.
If your axle is bolt-on on, removal and replacement will be a bit more straight forward. I say that with the utmost reservation, though. It is by no means an easy task. Only someone with mechanical know-how, the right tools, a safe level space to work and a helper to assist should even consider this undertaking. Just the weight of the new axle alone is too much for one person to handle. Please be safe and be smart!
Now, if you’re still persistent on installing yourself… First, figure out is if your existing axle is welded or bolted to the frame.
The axle attaches to the frame via mounting brackets. The mounting brackets are L shaped and welded to the frame. From there, the axle is either bolted or welded to the bracket. In newer Casita’s, the axles are bolt-on, welded on older models. It’s something easily seen by just getting under your trailer and inspecting the brackets. Our axle is a bolt-on, as shown in the picture.
Welded axles only come off one way – you cut them off! It can be a delicate job requiring skilled handling of a grinder. If you’re not comfortable with that, it’s best to seek help from a professional.
(Bolt-On Axle)
If your axle is bolt-on on, removal and replacement will be a bit more straight forward. I say that with the utmost reservation, though. It is by no means an easy task. Only someone with mechanical know-how, the right tools, a safe level space to work and a helper to assist should even consider this undertaking. The weight of the new axle alone is too much for one person to handle. Please be safe and be smart!
Ready to Replace Your Casita’s Axle!
With all this information, you are now equipped with all the knowledge we wish we would have known! Please feel free to leave questions in the comments below and let us know if this was helpful. It’s the best way to say thank you! 🙂
This was an very well written and extremely helpful article you put together, thank you very much! I just ordered my replacement Axle and will be installing it myself, you saved me a lot of time in research!
Terrific! I am happy to hear we helped save you some time! Cheers to many more miles!
Where did you order your axle from? Vern
Our 2003 Casita is coming up on 18 years and still running strong. We have been looking into a new set of brakes and started thinking about the axle. Hmmmmmm……yep! We should do that now rather than having a surprise while on the road. Thank you for the time and effort that you took to share your experience. We were surprised how inexpensive it is to purchase and install the axle. We do have the welded on axle, so I’m sure it will cost a bit more. We thought it would be a “breaking the bank” price. You have shut… Read more »
Chris, are you in OC California? Who are you using to handle the project? Thanks!
Great write up!! I’m looking to do a similar swap and thought I’d jack up the frame to mock the height of yours to look at the clearance. I would love to know the height of your step with the new 22 degree down axle. Knowing the height to the underside of the frame would be very useful as well. Thanks in advance!
How much clearance at tgif axle tube do you now have with the 22 degree down? Ours is an 09 with 10 degree down ,probably due. Considering the 22 of even the 45. Pulling with a Ram 2500. Can’t seem to find a chart with the axle lift/clearance for each compared to the neutral 10 degree up. I’ve considered the lift kit with shock kit, but might as well get the higher axle which would clear the axle tube more. Seems the shock kit won’t work, but they’re hard to come by and there’s a shop near Bryan can fabricate… Read more »
This was super helpful, I need to replace my 2005 axle and have been putting it off… I figured I needed to do a ton of measuring etc but Dexter just sent my build sheet and it’s so much easier now. Who did you use to order your replacement? Are you happy with the 22.5 down height, I’m debating between that and the 32 deg down but afraid it may be too tall. Mine seems so low now!
Exactly what I needed to know. Thanks so much!
We also live in Phoenix and need to order a new axle. Where did you get yours? Vern
Is it possible to share the tongue height when trailer is level on the 22.5 arms? What’s the hitch height?
And how’s the ride?
Thanks!
Where did you order your axle from? Vern
Where can I get a new axle? I live in Phoenix Az
Amazon has many such products
Great write up. One minor point, the standard Casita axle is 10 degrees up, not zero. Casita’s high lift option is 10 degrees down.
I have a 2002 casita 17’ with welded axle. I ordered an as built sheet from Dexter as you direct. I have been unable to find an rv, trailer or welding shop willing to order the axle from dexter and install. I found one that will install but I must provide the new axle. Dexter will not deal directly with me on the order. How did you manage this?
This is excellent! Dexter’s web site mentions the “New Dexter “Airflex–Air Ride Suspension System.” Is that a viable option for these axles? Thanks.
This exactly the write up I needed. Thank you very much for taking the time to do this.
One thing I would add is to take your camper and tow vehicle to a CAT scale often found at a truck stop. Usually for $20 or so, they can tell you the weight of your camper, and even the left / right ratio so you know how evenly it is loaded. Use this to determine which axle to replace the current axle with…
A local trailer company quoted me $1600 and 6 weeks to replace the 2006 axle that I removed myself. I just received one from Casita for $550+$280 shipping. They keep them in stock most of the time. I got it in about 3 weeks.
Thank you for the article. Any chance you have a copy of the final Dexter Build Sheet for your new 4,000 pound axle?
Excellent write-up. Your article had all the info I needed to order my new axle.
The only thing I had to consider after reading your article is if I wanted to use my same brakes or get new ones. After considering that I didn’t know the history of the existing brakes (I bought my Casita used) it would just make sense to order new brakes and upgrade the bearings at the same time.