torsion bar pivot in shell

[Larryjb]

I seem to recall seeing this before, along with a solution. Unfortunately I cannot find it anymore.

This bolt has pulled away and damaged the metal skin on the outside and inside. Does anyone remember the link to the problem and solution?

[HoMiPa]

I'd love to know the fix for this as well. I have the same problem with the front curb side attachment. It has pulled through the wall on both the interior & exterior sides. It's been that way for years, but since I'm doing all this work on my TM now, I'm trying to identify/remember all these little things that need to be repaired, so I can fix them.

[Larryjb]

Ironically, your reply puts me at ease to some degree. This tells me that the aluminum skins (inner and outer) are not significant structural supports for the shell-to-lift arms, if they can last in this condition for so many years.

I'd still like to see what solutions people have come up with. I remember seeing a solution that involved oversized washers. I've searched the frame and exterior subforums and not found it yet. Maybe I was dreaming that I read the solution.

[Bill]

Larryjb -

Your picture shows an acorn nut. If you unscrew and remove the acorn nut, you will see the threaded end of a bolt. The bolt goes through the entire wall. With the shell up, you can push the bolt through the wall and out the other side. You will see that most of the length of the bolt is smooth and unthreaded, suggesting a hinge pin function. It passes through an item called a "pocket stop", which is inside the wall. The pocket stop (which is adjustable, do a Search here on the Forum) is what limits the travel of the shell as you open it.

I think (but I do not know) that the deformation you are seeing comes from opening the shell too vigorously, so that it slams against the pocket stop at the end of its travel.

Getting the bolt back into the hole may require pushing a screwdriver through the hole, and then jockeying it around to line up all the parts.

Bill

[HoMiPa]

Ha ha Larry - yup - mine has been like that forever. It actually happened the first year of ownership, when during a sudden, unexpected storm, and away from the campground, the wind ripped the awning off the TM. It ripped the support arm brackets out of the exterior wall of the TM, along with ripping the awning off the top of the TM. I'm guessing the force of the wind pulling on the awning, etc, during that whole process, also caused that hinge pin bolt to rip through both sides of the TM upper shell wall. Not sure why it wasn't fixed when the new awning was installed, but it is definitely when it happened, which would have been summer of 2005. Been like that ever since. However, it does probably explain the problems I often have with flip up lock bar on that forward curb side bed support, in getting it to line up properly.

Thanks for the info Bill - so if I replace the bolt, should I just put a large washer on the inside and outside of the shell, to cover the aluminum rip? Does that bolt remain slightly loose, so that it does indeed act as a hinge pin, and therefore, washers may be a mute point because I won't be able to tighten the acorn nut onto the bolt all the way to hold the washers tight against the shell walls?

[Larryjb]

In Maria's picture of the pocket stop, there is no supporting hole in the U-shaped pocket stop bracket itself for the bolt that connects the lift arm to the shell, other than the aluminum skin itself.
Maria's picture of pocket stop:
http://3.bp.blogspot.com/_iZSRedBZ9n...Repair+023.jpg

When looking at the lift arm, it is clear that the lift arm would support the shell at the rubber bumper in the pocket stop.
Maria's picture of the lift arm in the upright position:
http://2.bp.blogspot.com/_iZSRedBZ9n...Repair+009.jpg

As the shell lowers, the lift arm will rotate counterclockwise until horizontal. In the horizontal position, I don't see any part of the lift arm that would support the shell at that rubber bumper in the pocket stop. I assume the weight of the shell would be taken by the inner walls at this point, but if the shell were forced closed with items packed too high in the TM, it could tear the aluminum skin.

I am concerned, though, that while raising the shell, the weight of the shell is supported by the skin of the wall itself. I believe that a large washer would just hide the problem, and it could get progressively worse of the years creating further alignment issues.

If I were to do anything, I think I'd have to remove the acorn nut and bolt, rivet a fresh piece of heavier guage aluminum to the side, drill a hole the correct size, then reassemble.

(Note, I would not use any form of steel here, as electrolytic action would degrade the aluminum.)

Thoughts? Am I overparanoid? (Wouldn't be a first for me)