October 3, 2019 NHTSA CAMPAIGN NUMBER: 19V702000

If the suspension fails, a sudden loss of vehicle control can result, increasing the risk of a crash.

NHTSA Campaign Number: 19V702

Manufacturer Jayco, Inc.

Components SUSPENSION

Potential Number of Units Affected 908

Summary

Jayco, Inc. (Jayco) is recalling certain 2017 Pinnacle Fifth Wheel trailers. The suspension system may fail.

Remedy

Jayco will notify owners, and dealers will inspect the condition of the leaf spring, rubber equalizer and bump stop clearance, and provide replacement of the leave spring or rubber equalizer if necessary. This repair will be done free of charge. Interim notices notifying owners of safety risk were mailed December 2, 2019. The recall began December 20, 2019. Owners may contact Jayco customer service at 1-800-517-9137. Jayco’s number for this recall is 9901443.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

NHTSA is missing critical, required information for this safety recall. This information must be supplied through the NHTSA Recalls Portal within 5 working days of confirming its accuracy:

– A description of the defect or noncompliance, including both a brief summary and a detailed description, with graphic aids as necessary, of the nature and physical location (if applicable) of the defect or noncompliance (49 CFR 573.6 (c)(5)).

– An identification and description of the risk to motor vehicle safety reasonably related to the defect or noncompliance (49 CFR 573.6 (c)(5)).

– A statement that the defect or noncompliance can cause a vehicle crash without prior warning; or a description of whatever prior warning may occur, and a statement that if this warning is not heeded, a vehicle crash can occur (49 CFR 577.5 (f)(1)).

– In the case of a defect, a chronology of all principal events that were the basis for the determination that the defect related to motor vehicle safety, including a summary of all warranty claims, field or service reports, and other information (such as numbers of deaths and/or injuries), with their dates of receipt (49 CFR 573.6 (c)(6)).

Pinnacle Suspension Inspection & Bump Stop Installation

Bulletin #:

19V-702 US

2019-551 Canadian

Make:

Jayco

Job Code:

9901443

Model:

Pinnacle FW

Flat Rate(s):

RC024 Inspect Vertical Axle Clearance .2 Hour

RC025 Inspect all 4 leaf springs .5 Hour

RC026 Replace 4 leaf springs 2.5 Hour

RC027 Replace 2 Rubber Shear Springs 1.7 Hour

RC028 Install 4 bump stops .7 Hour

Model Year(s):

2017

Incident:	Inspect Pinnacle Suspension System components for proper load dimensions. If dimensions are out of specification, the leaf springs and/or rubber shear springs may require replacement. Note: ALL units WILL require installation of four (4) rubber bump stops.
Affected Units:	ALL 2017 Model Year Pinnacle Fifth Wheels
Parts Kits: 19V-702A Bump Stop 19V-702B Steel Leaf Spring 19V-702C Rubber Shear Spring	19V-702A Bump Stop Kit–*4 per Unit* (Quantities shown below are per unit) 4-Bump Stop Assembly Jayco #2000322 8-Hex Bolts 5/16-18 x 5” GR5, Jayco #2000323 8-Washer Flat 5/16, Jayco #0011766 8-Washer Lock Split 5/16, Jayco #0011773 8-Nut Hex 5/16-18 GR5 Jayco #0011665 1-Gauge Block Wood 2 ¾” x 2 ¾” x ½” Jayco #2000321 19V-702B Leaf Spring Kit–*4 per Unit* (Quantities shown below are per unit) 4-Double eye- 7-leaf spring stacks w bronze bushings, Jayco # 2000292 8-U bolts .56-18 x 7.25” Zinc, Jayco #0309179 16-Nut Hex .56-18 GR8 Zinc, Jayco #0309194 (u bolt) 16-Washers, Flat Hardened 9/16, Jayco #0088280 (u bolt) 8-Bolt Shackle (Wet) Shoulder .56 x 3.24”, Jayco #0315400 (leaf spring) 8-Nut .44-20 Prevision TQ Zinc, Jayco #0297635 (leaf spring) NOT IN PARTS KIT 4-Leaf Spring tie plates, use component on repair unit 19V-702C Rubber Shear Spring Kit–*2 per Unit* (Quantities shown below are per unit) 2-LRE4000-24 Rubber Shear Spring, Jayco #0276717 1-LRE4000-24 Hardware Installation Kit, Jayco #0276718
Misc. Tools & Supplies:	Screw gun 1/2″ socket & ratchet 1/2” wrench Tape Measure & 28” long steel straight edge Torque Wrench Adjustable (0-50 Ft/lbs.)

Section I: TRAILER SUSPENSION COMPONENT INSPECTION

These instructions detail the inspection and service work required on the 2017 Pinnacle fifth wheel as follows:

Section I: Provides steps required to inspect the suspension components and installation of a rubber bump stop above each axle in four locations.

Section II: Provide the detailed instruction for removing and replacing Steel Leaf Springs

Section III: Provide the detailed instructions for removing and replacing the rubber shear spring

Section I – Step 1: INITIAL SETUP OF THE TRAILER

STEP 1:

Position the unit on a flat level surface.
Support the unit on the pin box using a suitable stand or a forklift (Fig 1).
The unit must be in a level condition.
Retract ALL stabilizer jacks.
The unit can be in an “as loaded” state, however not to exceed 3500 pounds for any one tire.
Record tire weights on inspection sheet in the space provided (page 3 of this document)

Section I – Step 2: VERTICAL AXLE TRAVEL USING A GAUGE BLOCK

STEP 2:

Inspect the vertical axle travel distance by placing the 2 ¾” gauge block (from the kit) between the top of the axle tube and the bottom of the 2”x 3” hanger tube as shown in Fig. 2. Repeat inspection at the four (4) axle locations. Write Pass or Fail in the space provided ion the inspection sheet (page 3 of this document).
PASS: Gauge block fits in the space between axle tube and hanger tube at all four (4) axle locations. GO TO STEP 5.
FAIL: IF THE GAUGE BLOCK FAILS TO FIT IN ONE OR MORE OF THE FOUR (4) LOCATIONS GO TO STEP 3.

NOTE: The gauge block measurement method shown in figure 2 may need repeated after STEP 3, and again after STEP 4 depending on the components changed.

Section 1-Step 3: INSPECT LIPPERT STEEL LEAF SPRINGS

STEP 3: PARTS KIT 19V-702B MAY BE REQUIRED

Count the number of leaves that make up the leaf spring (6 or 7).
Record this number on the inspection sheet (page 3 of this document). Enter the number under the “AS FOUND” section.

FIG 3:

Place a 28 inch long steel straight edge so it rests on top of the spring tie plate.
Steel straight edge needs to be 28 inches long so it can balance on the spring tie plate and extend out to the end of each spring to make measuring easier.

FIG 4:

Measure the vertical distance between the bottom of the straight edge, and the bottom of the upper shackle bolt threads (located at the equalizer) (between arrows in photo).
Measure this dimension on ALL
Record dimensions for all springs on the inspection sheet (page 3 of this document) under “AS FOUND” section.

FIG 5:

Measure the vertical distance between the bottom of the straight edge, and the bottom of the spring hanger bolt thread section (between arrows in the photo).
Measure this dimension on ALL
Record dimensions for all springs on the inspection sheet (page 3 of this document) under “AS FOUND” section.
These two dimensions will give you the approximate vertical distance from the spring eye to the tie plate. This is how the flatness of the spring under load is determined.
PASS: If all of the leaf springs measurements were greater than 3-1/2 inches, but the gauge block fails to fit into the space between the axle tube and the hanger tube (Fig 2), in one or more of the 4 axle locations…GO TO STEP 4.
FAIL: If ANY of the leaf springs measurements are less than 3-1/2 inches, ALL (4) leaf springs will need replaced.
- Remove the 6-leaf spring and replace with a 7-leaf springs in accordance with the instructions from Lippert Components, Inc (the axle manufacturer) found on pages 10 through 19 of these instructions.

Repair inspection – After ALL leaf springs are replaced you will need to recheck the clearance between the axle tube and the hanger tube (Fig 2), using the SAME gauge block provided in the kit.

PASS: Recheck spacing using the gauge block and if it now fits between the axle tube and the hanger tube (in all 4-locations), record results in the “As-Repaired section of the inspection sheet (page 3 of this document), THEN PROCEED TO STEP 5.
FAIL: If after replacing the springs, the gauge block fails to fit between the axle tube and the hanger tube in any or the 4 locations, THEN PROCEED TO STEP 4.

Section 1-Step 4 RUBBER SHEAR SPRING INSPECTION

STEP 4: PARTS KIT 19V-702C MAY BE REQUIRED

4.1 Inspect the LRE 4000-20 rubber shear spring for damage according to the MORryde inspection instructions (page 20 of this document).

PASS: If there is no damage to the 4000-20 rubber shear spring, GO TO STEP 4.2.
FAIL: If the 4000-20 rubber leaf spring has damage, replace both spring blocks with the LRE 400024 rubber shear springs from the kit. Installation shall be in accordance with the MORryde instructions (page 21-27 of this document). Refer also to the LRE Suspension System Owner’s Manual from MorRyde.

4.2 If the leaf spring measurements were correct (greater than 3-1/2 inches) but the 2 ¾” gauge block did not fit between the axle tube and the hanger tube, then the MORryde Rubber Shear Spring requires replacement.

Remove the MORryde LRE 4000-20 rubber shear springs and replace them with the LRE 4000-24 rubber shear springs. Installation shall be in accordance with the instructions from MORryde instructions (page 21 – 27 of this document). Refer also to the LRE Suspension System Owner’s Manual from MORryde.
After replacing both rubber shear springs, recheck the axle vertical clearance (Step #2) using the gauge block provided (fig 2). Write Pass or Fail in the “As-Repaired” section of the inspection sheet (page 3 of this document).
PASS: if the clearance is now sufficient for the gauge block to fit between the axle tube and the hanger tube, THEN PROCEED TO STEP 5.
FAIL: if the gauge block still fails to fit between the axle tube and the hanger tube (after replacing the leaf springs and the rubber shear springs), you will need to call Jayco Customer Service for further information on how to evaluate this unit.

Section II-Step 5 INSTALLATION OF RUBBER BUMP STOPS (4 TOTAL)

STEP 5: PARTS KIT 19V-702A IS REQUIRED ON ALL UNITS

Install the rubber bump stops ONLY if the gauge block has successfully fit into the space between the axle tube and the hanger tube behind each wheel, FOUR (4) locations. Reference (Fig 2).

FIG 6:

Bump Stops (4 per unit).
Mounting hardware for one bump stop: two 5/16-18 x 5” Gr5 hex bolts, two 5/16 Gr5 flat washers, two 5/16 Gr5 lock washers, and two 5/16-18 Gr5 hex nuts.

FIG 7:

Position the bump stop over the top of the axle between the spring hanger U-bolts.
Spring pack will fit in the notches on each leg of the bump stop bracket.

FIG 8:

Install two 5/16-18 hex bolts through the holes in the bump stop bracket. Place a flat washer, lock washer and nut on each of the bolts.
Torque to 10-12 Ft/lbs. (nuts should be tightened together) FIG 9:
Completed bump stop for one axle location.
Repeat installation process at all three (3) remaining wheel locations.

REFERENCE SECTION: SUGGESTED TOOL LIST FOR CHANGING THE STEEL LEAF SPRINGS & RUBBER SHEAR SPRINGS

The photo above shows the following tools:
½ inch drive Adjustable Torque wrench (zero – 50 Ft/lbs.) (not shown)
½ inch ratchet
3/8 inch ratchet with 16mm socket
Punch (approximately 3/8” diameter)
Small Sledge hammer
28” long steel straight edge
Impact driver with following ½” drive impact sockets: 11/16, 13/16, 14mm, 15mm, 17mm, 19mm
Screw gun with 6” long 3/8” nutsetter bit (or standard 3/8” nutsetter bit with 6” bit extension)
Drill with a 3/16” drill bit
Tape Measure
Mechanics Creeper
Grease Gun with a tube of Wheel bearing grease Jayco p/n 0230435
Lippert Manuals:
Wet Bolt Installation (p/n ccd 0002018)
Axle and Suspension Installation (p/n ccd 0001412)
Trailer Axle Owner Manual 2K-7K

REFERENCE SECTION: PHOTOGRAPHS FOR STEEL LEAF SPRING KIT, RUBBER SHEAR SPRING KIT & RUBBER BUMP STOP KIT

RUBBER BUMP STOP 19V-702A

Required on ALL Units

RUBBER SHEAR SPRING

& OWNERS MANUAL 19V-702C

Required based upon Inspection results

STEEL LEAF SPRINGS 19V-702B

Required based upon inspection results

The photos above show suspension component replacement

TI-345

LEAF SPRING REPLACEMENT ON AN EXISTING AXLE BEAM

AXLES AND SUSPENTION

Purpose

This document outlines the process for replacing the double-eye leaf spring components on an existing axle beam assembly. The following procedure is applicable for both underslung—when the leaf spring is mounted, or “slung”, under the axle—and overslung—when the leaf spring is mounted, or “slung”, over the axle (Fig. 1).

NOTE: Images used in this document are for reference only when assembling, installing and/or operating this product. Actual appearance of provided and/or purchased parts and assemblies may differ.

Safety

Read and understand all instructions before installing or operating this product. Adhere to all safety labels.

WARNING

The trailer MUST be supported per manufacturer’s recommendations before working underneath. Failure to do so may result in death, serious personal injury, severe product and/or property damage.

WARNING

Always lift the trailer by its frame and never by its axle or suspension. Axle and suspension components are not designed, or rated, for the dead weight, point-of-contact loads that the trailer’s frame is. Do not go under the railer unless it is supported by appropriately rated jack stands.

Improperly supported trailers can collapse, causing possible serious personal injury or death.

CAUTION

Moving parts can pinch, cut or crush. Keep clear and use caution.

CAUTION

Wear appropriate personal protective equipment (PPE) when performing service or maintenance operations. Always wear eye protection when servicing trailer axles, brakes, hubs, springs and wheels. Not using PPE may result in personal injury.

Resources Required

1 -2 persons, depending on task
Floor jacks
Jack stands Torque wrench (ft-lb)
Pneumatic air or impact gun
Assorted deep well sockets
Hammer or mallet
Torque wrench (ft-lb)

Replacement Procedure

1. Using floor jacks, lift the frame slightly and place properly-rated jack stands under the axles (Fig. 2) so the shackle bolts can be driven out with a hammer.

2. Place a suitable block under the axle tube near the area to be repaired.

NOTE: The block acts as a support for the weight of the axle only, allowing suspended system components to be serviced or replaced freely. Multiple axle trailers MUST have the weight of each axle properly supported before disassembly of any suspension system components.

3. Remove tires and wheels—curbside and roadside—from the axle (Fig. 3) with the affected leaf spring. 4.

4. Set wheel and lug nuts (Fig. 3) aside for later installation.

5. Inspect axle/brake assembly electrical wiring and/or hydraulic hoses for length. If lines are too short to allow lowering the axle, disconnect lines before lowering.

NOTE: Make sure electrical power is off and hydraulic system has been de-energized before disconnecting lines.

6. With an impact gun or an appropriate wrench, loosen the nuts on the leaf spring bolts and the shackle bolts (Fig. 4).

NOTE: Hold the head of the bolts with a wrench.

7. Remove the nuts from the leaf spring bolts and the shackle bolts.

8. Drive out the leaf spring bolts with a mallet or hammer until they unseat from their hanger.

A. Inspect the threaded end of the bolts for damage to the threads.

B. If threads are damaged, replace bolts. Otherwise, set bolts and nuts aside for later installation.

9. Drive out the shackle (wet) bolts of the shackle link assemblies with a mallet or hammer until they unseat from their leaf spring and equalizer.

A. Inspect the threaded end of the shackle (wet) bolts for damage to the threads.

B. If threads are damaged on one or both bolts, replace shackle link assembly. Otherwise, set shackle link assemblies, shackle links and nuts aside for later installation.

NOTE: At this point in the installation, LCI recommends inspecting the equalizer shackle links. If the shackle links are worn, LCI recommends replacing them.

NOTE: Shackle links MUST be reinstalled using the same shackle orientation used previously.

10. Adjust the floor jacks so the jack stands can be removed from under the axle.

11.0Using the floor jacks, lower the axle of the leaf spring being replaced.

12. Position and orient the new leaf spring (Fig. 5) underneath the trailer to help expedite installation.

13. After the axle and leaf springs have been lowered from the chassis hangers and shackle links:

A. Remove U-bolt nuts (Fig. 6A) from the affected leaf spring.

B. Remove U-bolts (Fig. 6B) and tie (spring) plate (Fig. 6C) from the axle (Fig. 6E) holding the affected leaf spring (Fig. 6D).

C. Set U-bolts, nuts and tie (spring) plate aside for later installation.

D. Set removed leaf spring aside. Do NOT reuse affected leaf spring.

14. Place the new leaf spring (Fig. 6) onto the axle with the leaf spring clip pointing towards the front of the trailer. Make sure spring center bolt engages the center hole of the tie (spring) plate.

15. Position U-bolts and tie (spring) plate on the axle (Fig. 7).

A. Install washers, if equipped, and hand-start nuts. B. Hand-tighten nuts until snug (Fig. 7).

B. Verify the following:

C. Center bolt is engaged in tie (spring) plate (Fig. 7). Leaf spring is square to the axle (Fig. 7).

I. Center bolt is engaged in tie (spring) plate (Fig. 7).

II. Leaf spring is square to the axle (Fig. 7).

III. U-bolts are straight up and down and not splayed in or out.

IV. U-bolts have approximately the same amount of thread sticking out of each nut.

16. Progressively tighten tie (spring) plate nuts in a criss-cross pattern, in the order given (Fig. 8), until the final torque is obtained. Refer to Spring Axle Torque Specifications chart for bolt torque requirements.

Spring Axle Torque Specifications
Bolt Type	Axle Capacity	Torque
³/8″ U-Bolt Nuts	2K	35 ft-lbs
¹/2″ U-Bolt Nuts	3.5K	50 ft-lbs
⁹/16″ U-Bolt Nuts	5.2K	65 ft-lbs
⁹/16″ U-Bolt Nuts	6-8K	90 ft-lbs
Spring Eye, Equalizer and Shackle Nuts	All Double Eye	30-50 ft-lbs

17. Verify the following:

A. Leaf spring is square to the axle.

B. Tie (spring) plate is flat against leaf spring.

C. U-bolts are straight.

D. U-bolts have approximately the same amount of thread sticking out of each nut.

E. All nuts are torqued.

18. Use floor jacks and jack stands to raise axle assembly into position for reinstallation to the trailer’s frame, do as follows:

A. Reinstall previously removed leaf spring hanger and shackle bolts and nuts.

B. When installing wet bolts, use a steel tube and hammer to drive in wet bolts to prevent damage to the grease fitting.

C. Refer to Spring Axle Torque Specifications chart for bolt torque requirements.

NOTE: Hold the head of the bolts with a wrench.

D. If installing new or previously removed wet bolts, apply new grease. Use NLGI code GC-LB.

E. Reconnect any disconnected electrical lines and/or hydraulic hoses (step 5).

NOTE: If reconnecting hydraulic hoses, make sure all hydraulic lines are purged of air.