Does the gap close up when you release the little aluminum bar that swings out and connects the upper shell to the lower box?
I had a similar issue caused by old torsion bars. BUT, that was with an 18 year old trailer, so I doubt that is the issue. However, you should verify that the torsion bar is in good shape.
1) When closed up (both shells down and latched, are all lift arms parallel to the trailer?
2) When set up, but unlatched (with those little aluminum swing out arms), and with the trailer perfectly level in all directions, are all lift arms perfectly vertical?
Also check that the side wall is vertical on both sides at the time.
3) When set up and latched, are the lift arms perfectly vertical still?
Also check that the side wall is still vertical.
The answer to question #1 will tell us if the torsion bar is bent. I doubt that it is, but it's worth checking anyway.
The answer to question #2 will tell us something about the torsion bar.
The answer to question #3 will tell us if latching the shell to the box is affecting the alignment.
Please keep in mind there is a tolerance in every measurement. If you measure #1 very carefully, I'm sure that there will be no trailer that is perfectly parallel to the 1/16" in 4 feet. But if it were out by an inch in 4 feet, that would be too much. I don't know what that tolerance should be, but your trailer could be within the designed tolerance.
Here are some possibilities:
1) torsion bar bent (unlikely)
2) bracket mount for torsion bar (at bottom edge of box) loose. (unlikely given the age, but possible).
3) box wall out of adjustment.
4) hole in aluminum swing out bar in wrong place.
I'm sure others will have other ideas as well.
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