Chassis, Brakes & Suspension

Complete under-carriage repairs, brake servicing & suspension upgrades.

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Caravan Chassis, Brakes and Suspension Repairs

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The chassis, brakes, bearings, axles, and suspension keep your van safe and stable while towing. Neglecting undercarriage maintenance can lead to dangerous failures at highway speeds. Regular inspection is essential.

With over 40 years of experience, our St Marys workshop features a state-of-the-art hoist system for full access to every undercarriage component.

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Chassis Repair

Rust removal, section replacement, crack welding, reinforcement, protective coatings, full chassis replacement for severely damaged frames, and drawbar repairs and upgrades.

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Brake Service

Brake shoe and pad replacement, drum machining, brake magnet testing, cable adjustment, electric brake controller setup, hydraulic bleeding, and breakaway system testing.

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Bearing Repack

Hub removal and inspection, cleaning and repacking with marine-grade grease, bearing and seal replacement, hub wear checks, and preload adjustment to manufacturer specs.

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Suspension Upgrade

Independent coil spring conversions, shock absorber fitting, heavy-duty spring upgrades, airbag suspension kits for adjustable ride height, and stabiliser bar installations.

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Axle & Spring Repair

Axle repairs and replacement, leaf spring service, U-bolt and shackle pin replacement, spring hanger repair, and heavy-duty upgrades for increased load capacity.

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Tyres & Wheels

Tyre condition and tread depth checks, tyre pressure inspection, wheel stud torque checks, new tyre fitting, damaged wheel replacement, and load rating advice.

Dario Caravans yard and workshop

Catching chassis issues early prevents dangerous failures and costly repairs

Chassis Repairs

Your chassis is the structural backbone supporting the entire caravan. Over time it can suffer rust, fatigue cracking, impact damage, and stress from overloading. We repair, reinforce, or replace affected sections -- including rust treatment, crack welding, protective coatings, and full chassis replacement when necessary.

Brake Servicing

We service all braking systems -- electric, electric-over-hydraulic, and mechanical override. Services include shoe and pad replacement, drum machining, brake magnet testing, cable adjustment, controller setup, hydraulic bleeding, and breakaway system testing. Unmaintained brakes cause reduced stopping power, sway, and potential failure.

Bearings, Axles and Suspension

We inspect and repack wheel bearings every 10,000 km with marine-grade grease, replacing worn components as needed. For axles and springs, we repair or replace leaf springs, U-bolts, shackle pins, and spring hangers for both single and tandem-axle setups. Suspension upgrades -- including independent coil conversions, shock absorbers, heavy-duty springs, and airbag kits -- dramatically improve ride quality on unsealed roads.

Caravans at Dario Caravans yard

Servicing every make and model for over four decades

Tyre and Wheel Service

We check tyre condition, tread depth, pressure, and wheel stud torque at every service. Correctly inflated tyres prevent blowouts and reduce damage risk. We also fit new tyres, replace wheels, and advise on correct specifications for your load rating.

Frequently Asked Questions

Caravan brakes should be inspected at every service interval, which we recommend every 10,000 kilometres or at least once per year. If you tow frequently, travel on unsealed roads, or notice any changes in braking performance such as pulling to one side, unusual noises, or increased stopping distances, have your brakes checked immediately. Electric brake controllers should also be tested and adjusted regularly.

Common signs of worn caravan wheel bearings include a grinding or humming noise from the wheels while towing, excessive heat coming from the wheel hub after driving, visible grease leaking from the hub, a wheel that wobbles or has play when jacked up, and uneven tyre wear. Worn bearings are a serious safety issue and can lead to wheel failure if not addressed promptly. We recommend bearing inspection and repack at every service.

Yes, chassis rust repair is one of our core services. We can cut out and replace corroded sections of your chassis, weld in new steel, apply protective coatings, and reinforce weakened areas. For caravans with extensive chassis rust, we can assess whether a full chassis replacement is more practical. We also treat and protect chassis components to prevent future corrosion, which is especially important for vans that travel in coastal or wet environments.

Yes, we offer a range of suspension upgrades to improve your caravan towing experience. Options include upgrading from leaf springs to independent coil suspension systems, fitting shock absorbers, upgrading to heavy-duty springs for increased load capacity, and installing airbag suspension kits for adjustable ride height and load levelling. We can recommend the best suspension setup based on your caravan type, weight, and how you use it.

Need Chassis, Brake, or Suspension Work?

Contact our team to book an inspection or discuss your under-carriage repair requirements.