Slide failure and broken mount

[Jon-Laura N]

We were camping this weekend and the side slide on our 2007 Jayco Jay Feather EXP 29A failed during opening. I assumed it was just a broken gear and not much of an issue. With a little giggle and wiggle we got it to fully extend. This is our first travel trailer but I have helped my brother for many years redo and repair his. At the end of the weekend bringing the slide back in was a challenge. I had to grab the socket set (I guess I really should have checked when we purchased it to see if there was a manual slide crank handle) and began to crank in the slide. All seemed to be going as planned with a little more wiggle giggle and just about 75% of the way in the motor and worm gear fell off onto the floor. I spoke with Jayco yesterday about part information because I couldn't find much online that looked remotely close to what I have and they were as helpful as they could be without the serial number. I'll get some pics and post as things move along so that it may help someone else out down the road. At least it was the last trip of the season.

[Jon-Laura N]

So I spent some time talking with Jayco first with the regular parts department before talking with a parts specialist and they were very helpful. They provided me with a breakdown drawing of my slide mechanism so that I was able to identify what the problem may be and what parts were available. Along with an installation manual on the proper installation and setup of the slide unit.





It took my brother and I about an hour start to finish to remove the unit. Most of the time spent making sure we had a plan and any results that may occur from our actions. Pushing open the slide and removing the four bolts from underneath before closing the slide and removing the other five bolts.




With the unit removed we looked everything over and found that the only problem was the factory welds between the drive mounting plate and channel did not penetrate. This 'cold' weld failure was due to improper welding temperature and speed resulting in a surface weld which caused the drive mounting plate to break away from the channel.





Next step is to remove the bad cold welds, review ALL of remaining welds on the unit, make sure the unit is square and press out any bends that may have occurred in the unit before properly welding it. I'll take a few more pictures during the install process and follow up.

[Jon-Laura N]

I suppose I should have first put the picture up of the slide unit in the floor.

[Jon-Laura N]

The repair actually wasn't to bad. It took my brother and I an hour to pull out the slide mech taking lots of pictures along the way. So we knew what went where and what screws were removed. I did mark the height of the brackets in relation to one another prior to removing it as to make sure I had it set right when we put it back together.


At this point the flexible hose for the HVAC was in the way and damaged. That being the case one was cut and replaced after the project was complete. The other was disconnected at the connection point under the dining table seat. All I had to do was remove the single screw and rotate the connection to release if from the main duct.


We pushed the slide part way out and took out the couple lag bolts from the channel from the outside. We then pushed it back in and took the remaining lag bolts out. At that point we pushed up on the slide from the inside and slide the channel out. The slide itself rests on the rollers toward the outside frame of the slide unit so there was no problem moving it or damaging it.


Then taking out the few remaining bolts that were left in the base brackets to the floor. The slide sits on the two outbound rollers so that wasn't an issue. We pushed the slide closed and secured it with the travel bar to seal it closed. Be careful of the plastic washer/bushing on the slide wheels they will pop out.


With everything out we reassembled it on the work bench before grinding and squaring everything back up. Putting a few tack welds on everything before hooking it to a battery running it in and out to verify there were no alignment issues. We welded the unit up fully and drilled some additional holes in the slide channel (that mounts under the couch) along with a few more in the bracket that mounts to the slide wall at the.


Putting it back in took an hour and was just like the removal pushing out the slide part way to get the lag bolts in the slide channel first. Doing it again I would have assembled the slide unit as one piece before putting it under the couch. We did it part by part and had to take it back out to put two bolts in the upper frame. It wasn't a tough job it just took some time to figure it all out. Additional holes were drilled in the frame just below the slide itself where the bar mounts to the wall for additional lag bolts.


As for the 2 flexible ducts, the torn duct was replace with new flexible duct from Lowes (Its just standard flexible HVAC duct I think some call it dryer vent duct) and the second was reconnected. Hardest thing was getting my big hands in between the wheel well and slide to route it back through.


All in total the job was not as bad as I thought it was going to be it just took some time and a bunch of pictures. I think anyone that is handy and can turn a wrench could do it. As for the welding of the slide mech frame any shop with a mig welder could do it at a reasonable cost. It does take two people to do the job that's for sure, holding the slide in place and tilting it to put in screw or remove parts is not a one person job. I add some pics here as soon as I get a chance but as for now its camping season.


On a side note... With the unit all back together and in use the clicking for the clutch when the slide is all the way in or out no longer clicks. I'm not sure if I have something to tight when I reassembled it or if there is an issue with the clutch itself. As for now we are using it and I'll look into it when the weather cools down or tiem allows. Happy Camping

[eldermike]

It's good to see people that can turn wrenches and weld things still exist in this world. Good job. Question: if you are not hearing the clicking is the motor just going into stall?