Sunline RV Forum
Sunline User Photos

Go Back   Sunline Coach Owner's Club > Technical Forums > Repairs and Maintenance
Click Here to Login

Join Sunline Club Forums Today


Reply
 
Thread Tools Search this Thread Display Modes
Old 04-25-2014, 10:45 AM   #1
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
Hensley Arrow Hitch Rebuild

I just picked up a used Hensley Arrow Hitch and I thought I would share the refurbishment of it. I've had my eye on these for years, but could never justify the high price tag they demand. By all accounts they work as advertised so I'm excited to find out for myself.

I wasn't really actively looking for one, but the thought crossed my mind, so I did a Craigslist search, saw one was for sale nearby and it had been for sale for quite a while. After contacting the seller to get some details, then I made an offer for what I was will to pay ($800) and he accepted it!

I called Hensley to get details based on the serial number (and to make sure it wasn't reported stolen or something weird), It was all good and this one was originally sold in 2004. It doesn't appear to have had a ton of use, but I'm sure it has been outside for most all it's life. The powder coat on these things apparently is notoriously bad this one was no exception. But I wouldn't expect it to be shiny after 10 years either. Anyway, I like to really go through things like this so I know exactly what the true condition is, replace anything if needed and really get a good understanding of how things work. I don't like to wonder and worry about the maintenance history. So here are a few of pictures of the tear down so far.

Here are the first few pictures of the tear down. There are 8 cone bearings & races just like your wheel bearings. There are 4 shafts with 2 bearings on each shaft. Now these things aren't spinning like wheel bearings are, just back and forth a few degrees, but I was concerned about water intrusion after 10 years and my concern turned out to be justified.

These pics are of the lower unit (black part) that attaches to the truck via hitch bar. You can see one of the bearings grease is pink, instead of dark red. The pink one has seen water. The upper seal had failed. The bearings on that side were actually starting to rust a bit. The upper bearing would not slide off due to a tiny amount of rust on the shaft and a close tolerance. I started to really worry this might be a bit of a nightmare to get off, but a gentle pull with my puller and it easily came free. Of course I ruined the bearing doing this, but it was already slightly pitted and was going to be replaced anyway. The others all look fine and will just get repacked and new seals. Next is cleaning up all that grease and grime, then it will soak overnight in Evaporust, then remove any remaining loose paint, prime, paint, repack, reassemble, install, then I think we will go camping.
Attached Images
File Type: jpg hensley2.jpg (21.4 KB, 33 views)
File Type: jpg IMG_6807.jpg (91.6 KB, 34 views)
File Type: jpg IMG_6812.jpg (84.7 KB, 24 views)
File Type: jpg IMG_6815.jpg (105.5 KB, 24 views)
File Type: jpg IMG_6818.jpg (118.3 KB, 23 views)
File Type: jpg IMG_6821.jpg (80.0 KB, 26 views)
__________________

__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 04-25-2014, 10:55 AM   #2
Senior Member
 
bunjin's Avatar
 
Join Date: Apr 2013
Location: Connecticut
Posts: 759
SUN #5039
bunjin is an unknown quantity at this point
Thanks for sharing and the pictures. I will be interested on the field report!
__________________

__________________
TT:1983 Sunline T-1550
TT:1996 Sunline T-2053
TV:2005 Toyota Tundra Double Cab 2UZ-FE i-Force 4.7 L DOHC (MFI) V8 4WD SR5 Automatic
P3 break control
"I know a lot about nothing and nothing about a lot"
bunjin is offline   Reply With Quote
Old 04-25-2014, 10:42 PM   #3
Moderator
 
JohnB's Avatar
 
Join Date: Nov 2006
Location: Ohio
Posts: 9,348
SUN #89
JohnB is an unknown quantity at this point
Scott, you scored big time!!! You have a fine piece of equipment there and once you get it all cleaned up, you will be a happy camper once it is all setup.

While you have it all stripped down and cleaned up, before painting wire brush and check the welds on the WD bar sockets. Bright light and look close. If by odd chance you have a buddy in a weld shop, they have dye penetrate that will confrim the welds are sound or not if any look in question.

In heavy use they have cracked before in the WD bar sockets. That said yours does not show the signs of heavy use as the WD bar sockets look nice and true round. They get wallowed out with heavy use and lack of lube. Odds are high yours is good by the looks, just now is a heads up to look while it is stripped down.

The stinger, you may or may not need a different rise/drop, you will know once you get it setup. if you do not have one, Hensley has a full instruction 42 page manual on line. See here for a copy User Manual Downloads - Hensley Mfg., Inc.

I have several campers buds with these and they do work as advertized. The only heads ups up it to make sure you adjust the brake controller so the trailer brakes leads the truck to keep the linkage in tension to not accidentally get the Hensley bump.

Good luck and you will be a happy camper towing.

John
__________________
Current Sunlines: 2004 T310SR - Fern Blue, 2004 T1950 - Fern Blue, 2004 T2475 - Nutmeg
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC

Google Custom Search For Sunline Owners Club
JohnB is online now   Reply With Quote
Old 04-26-2014, 09:24 PM   #4
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
Thanks John! It doesn't seem to have had a lot of use. The spring bar bushings are designed as a wear part and don't appear to much wear at all. Almost no wallowing. Unless they were replaced at some point, but I doubt it. I'll be inspecting the welds as best I can when it's stripped. Anything suspect I will have it checked out.

Since you mentioned it...I got a bit of a surprise last fall when I noticed my stainless drawbar, that I use for my light utility trailer (only 2" ball), had a significant crack in it. I really never thought I would see something like this especially in something that is rated so much higher than what it was ever used for. I'll be keeping a closer eye on all the components in the towing system from now on. Pics of the cracked draw bar attached.

Note: These pics are NOT of the Hensley.
Attached Images
File Type: jpeg IMG_5592.jpeg (83.6 KB, 15 views)
File Type: jpeg IMG_5593.jpeg (128.7 KB, 12 views)
File Type: jpeg IMG_5594.jpeg (133.7 KB, 11 views)
__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 04-28-2014, 12:58 AM   #5
Moderator
 
Sunline Fan's Avatar
 
Join Date: Dec 2006
Location: Michigan
Posts: 5,805
SUN #123
Sunline Fan is an unknown quantity at this point
Nice score! I have a buddy whose parents have a Hensley sitting in their garage- they bought it in '98 shortly after buying a 30' Nomad. They used the trailer a good amount the first few years, but then as the kids got older, it just sat. Sat in a storage lot for over 10 years until they sold it, but they delivered it to the campground for the people and kept the hitch. When funds allow, I thought about picking it up from them since it is supposed to be better than my dual cam setup. It's probably in similar condition to yours.
__________________
2007 T-286SR Cherry/Granola, #6236, original owner, current mileage: 9461.2 (as of 10/01/16)
1997 T-2653 Blue Denim, #5471
1979 12 1/2' MC, Beige & Avocado, #4639
Past Sunlines: '97 T-2653 #5089, '94 T-2251, '86 T-1550, '94 T-2363, '98 T-270SR
Sunline Fan is offline   Reply With Quote
Old 04-28-2014, 06:11 AM   #6
Senior Member
 
jim44646's Avatar
 
Join Date: Jul 2012
Location: Ohio
Posts: 996
SUN #4040
jim44646 is an unknown quantity at this point
Since you have it stripped dawn get it powder coated. it will look like new.
__________________
Jim and DW Darlene
2001 T-2553 Sunline Solaris
2006 GMC Sierra Duramax 2500HD 4X4
Firestone Transforce AT tires
Reese Dual Cam Sway Control
jim44646 is offline   Reply With Quote
Old 05-03-2014, 07:50 AM   #7
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
Just thought I would update my progress on the hitch rebuild. Since we've had about 6 straight days of rain around here and I couldn't work on the camper, it gave me an opportunity to keep going on this hitch.

When I removed the other 2 sets of bearing from the upper section of the hitch they both had water damage and rust in them. You wouldn't have know they were bad by just rotating the hitch around and maybe I could have got away with just cleaning them all up, but since I'm going through all this work, I went ahead and replaced all 8 bearings and races. I doubt they would have ever actually failed, because there is such little motion, but much longer without use, things were probably going to seize up. I ordered new bearing caps (those silver half domes) from Hensley and I think they are the weak link for water intrusion. I will probably use a little RTV Silicone on the mating surfaces when I reinstall them to ensure no more water infiltration....
Attached Images
File Type: jpg IMG_6888.jpg (73.6 KB, 15 views)
__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 05-03-2014, 07:57 AM   #8
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
After complete disassembly, I soaked some of the unpainted rusty parts in Evaporust (a wonderful non toxic de-rusting solution) and the greasy rusty parts in my electrolysis tank to remove the rust grime and hopefully the powder coat. You can see how the water - baking soda solution starts clear, and after applying power with a battery charger (after 24 hours) the rust transfers from the part to the cast pipes. You can see tiny bubbles immediately after you apply power. I used 12v and 10 amps. It's a super simple setup and it works wonderfully. Science is so cool! I know electrolysis will strip off many layers of paint, but never tried to remove powder coat with it. I'll save you the suspense, it does not The powder coat was in terrible shape, I could get under it with a knife and flake up big pieces all over the place. Even in places that it was hard to get off, I still found rust under it. I'm beginning to despise powder coat...too many failures and too hard to fix them. Painting over the remaining powder coat would have been a bad idea. It just was not well adhered anymore. So off to the sand blaster the parts went. As I understand it, sometimes even sand blasting can't effectively remove powder coat and it needs to be baked off. This time it came off fine.
Attached Images
File Type: jpg IMG_6882.jpg (91.7 KB, 11 views)
File Type: jpg IMG_6886.jpg (109.0 KB, 12 views)
File Type: jpg IMG_6885.jpg (66.3 KB, 14 views)
File Type: jpg IMG_6887.jpg (93.4 KB, 10 views)
File Type: jpg IMG_6889.jpg (86.5 KB, 11 views)
__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 05-03-2014, 08:00 AM   #9
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
I've got all 8 races pressed back in, and everything now ready for paint. I'll be painting next week. I'll be using, low gloss black, Valspar Tractor and Implement Primer and Paint with a hardener additive. Sounds like the tractor restoration guys really like it for an affordable durable paint for metal. If it's good enough for the tractor resto guys, should be good enough for my hitch!
Attached Images
File Type: jpg IMG_6892.jpg (92.2 KB, 17 views)
File Type: jpg IMG_6927.jpg (84.3 KB, 14 views)
File Type: jpg IMG_6928.jpg (91.9 KB, 14 views)
File Type: jpg IMG_6929.jpg (84.1 KB, 16 views)
File Type: jpg IMG_6924.jpg (69.5 KB, 16 views)
__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 05-03-2014, 07:20 PM   #10
Senior Member
 
Gene's Avatar
 
Join Date: Jan 2009
Location: Rhode Island
Posts: 1,515
SUN #768
Gene is an unknown quantity at this point
WOW!!! Great work and FANTASTIC pictures, thanks for posting them. That hitch will be better than new.
__________________

Gene & DW Ginny
2002 Sunline T-2363
2008 Toyota 4-runner 4wd 4.7L V-8
Reese Dual Cam straightline - P3 Brake controller
Gene is offline   Reply With Quote
Old 05-03-2014, 10:41 PM   #11
Moderator
 
JohnB's Avatar
 
Join Date: Nov 2006
Location: Ohio
Posts: 9,348
SUN #89
JohnB is an unknown quantity at this point
Scott, your handy work is very good

Your doing a 1st class job! I agree on the bearing caps, and the RTV trick. I was thinking that as I read your post and sure enough you did it. Hensley's paint job has been known to be an issue. With such a good quality product, they should help the paint issue.

Equipment enamel, yes a good choice. I have a 35 year old Ford tractor still with the original paint job and it does not flake. Fade yes, but not flake. And it has live through some real outdoor messes and produce spay over the years. A proper paint job with the right product done right, will out last the camper and the hitch.

Thanks for sharing.

John
__________________
Current Sunlines: 2004 T310SR - Fern Blue, 2004 T1950 - Fern Blue, 2004 T2475 - Nutmeg
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC

Google Custom Search For Sunline Owners Club
JohnB is online now   Reply With Quote
Old 05-10-2014, 10:29 PM   #12
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
Another update on the hitch progress...everything is now primed and has 2 coat of Valspar tractor paint w/ enamel hardener. Getting good and dry over the weekend. Will reassemble this week!
Attached Images
File Type: jpg IMG_6970.jpg (71.0 KB, 17 views)
File Type: jpg IMG_6971.jpg (104.0 KB, 20 views)
File Type: jpg IMG_6972.jpg (101.9 KB, 17 views)
File Type: jpg IMG_6974.jpg (111.2 KB, 18 views)
__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Old 05-10-2014, 11:11 PM   #13
Moderator
 
JohnB's Avatar
 
Join Date: Nov 2006
Location: Ohio
Posts: 9,348
SUN #89
JohnB is an unknown quantity at this point
Looks good! It will for sure out last the original paint job.
__________________
Current Sunlines: 2004 T310SR - Fern Blue, 2004 T1950 - Fern Blue, 2004 T2475 - Nutmeg
Prior Sunlines: 2004 T2499 - Fern Blue
2005 Ford F350 Lariat, 6.8L V10 W/ 4.10 rear axle, CC, Short Bed, SRW. Reese HP trunnion bar hitch W/ HP DC

Google Custom Search For Sunline Owners Club
JohnB is online now   Reply With Quote
Old 06-09-2014, 08:39 AM   #14
Senior Member
 
Join Date: Feb 2008
Location: Minnesota
Posts: 167
SUN #527
ScottK
Final update on the rebuilt Hensley. Looks good and should last me many years. I used a little RTV Silicone when installing the new bearing caps, so hopefully that eliminates any future water intrusion.

(don't mind those 2 rusty washers on top, they have been replaced since the pictures)

I installed new chains instead of just extending my old ones. And I just didn't feel right about installing that freshly painted hitch on a scungy looking tongue...so I repainted it as well....ah yes, that's better.

On a couple short trips, it seems to work just as advertised - didn't feel any sway from the wind or passing trucks. Sweet.
Attached Images
File Type: jpg IMG_7071.jpg (108.2 KB, 16 views)
File Type: jpg IMG_7073.jpg (82.5 KB, 16 views)
File Type: jpg photo 1.jpg (134.6 KB, 16 views)
File Type: jpg photo 2.jpg (152.3 KB, 17 views)
__________________

__________________
1988 Saturn T-1550 (sold 6/10)
2004 Solaris T-1950 (sold 5/14)
2007 Solaris T-276SR
2012 Toyota Tundra Crewmax
ScottK is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
1992 24' Sunline Solaris T-2490 Rebuild Pics Rich Nagel Repairs and Maintenance 0 06-17-2008 09:15 PM
Whoa Nelly! Hensley just called > go figure! bugbite Towing and Tow Vehicles 11 07-23-2007 06:26 AM
Hensley Arrow & Other Hitching Aids & Ideas PTHutch Modifications 2 07-19-2007 01:25 PM
? Weight of a Hensley Arrow ? bugbite Towing and Tow Vehicles 17 07-05-2007 12:06 PM
Hensley Arrow With T-1950 wobbly Towing and Tow Vehicles 9 03-31-2007 11:37 PM



» Featured Campgrounds

Reviews provided by

Disclaimer:

This website is not affiliated with or endorsed by Sunline RV or any of its affiliates. This is an independent, unofficial site.


Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -6. The time now is 11:34 PM.