This has seen more post activity than expected sadly with little acknowledging the information sought. While on the bandwagon, the biggest issue I have been able to identify is failures with the lifting mechanism of the Karavan. This was resolved in around 2009/2010 with a redesign that drop the lift load considerably.
Chester - Thanks for your input. Were you using the shower screen? I was concerned about this aspect but would knowing the floor is all fully sealed it is easily wiped up. I think I will still use the external shower tent except in caravan parks but will be handy for showering the kids out of the cold.
HKB - Thanks for the feedback. Are you able to shed any further light on this ie year model, circumstances, actual failure etc?. As others have said, there was a run of defective trailing arms due to an isolated welding issue and also some from what I understand with the wider offset trailing arms to suit 200series cruisers. The design was modified but I presume will always be inherently weaker than the 0 or +30 track due to the additional leverage of the +70. I won't be using the latter.
. I am not sure that KK are losing the passion. Yep, I am sure Bruce Loxton is loaded but have a chat to him at a 4wd/camping show. I have seen him at every one I have been to in Sydney over the last 2 years (Only lived in Sydney that long). Chatting to him recently he is clearly passionate about his products but that passion extends to the environment and green technology. An interesting guy who knew his product!
Jason - Are there really issues with the Fox shocks? I haven't come across anything on this before and have them fitted to my current KK. They may have a heat reactive paint (not sure) but they actually have temp gauge on them for you to check whether you are pushing to hard or not. ie slow down or drop tyre pressures further etc. The Fox shocks are also fully rebuildable and do have a history in performance suspension.
Gronk - Similar to Jason. My current KK (2013 build) is of brilliant quality and have no doubts over its structural integrity.
KeithB - Have a read of the downloadable articles. They provide a good understanding of the whys in all of their designs. As per Jason, I don't see anything wrong with the BFG AT's that come with it standard. Why would you want to fit 10ply tyres to anything when it isn't required knowing that it will put undue stress on components regardless of their strength.
Rumpig/Diesel Power - I have logged onto the KK portal but haven't been able to find anything but useful tech info like the dealer product training info, schematics for wiring etc. I have come across the KKOG but don't know if there is any formal affiliation with KK. You have to pay to join and my first impression is that it is a bunch KK Owners who only want to associate with other KK Owners because they think they are somehow better. I would love to be corrected on this as it shouldn't matter what equipment others use.