9901513 – Leaf Springs Provide Inadequate Suspension Support – 2017 Jayco North Point Fifth Wheel Trailers

July 2, 2020 NHTSA CAMPAIGN NUMBER: 20V385000

Leaf Springs Provide Inadequate Suspension Support

Tires contact with the wheel well or surrounding structure may cause damage to the tire, or cause premature tire wear, and loss of control, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V385

Manufacturer Jayco, Inc.

Components SUSPENSION

Potential Number of Units Affected 1,409

 

Summary

Jayco, Inc. (Jayco) is recalling certain 2017 North Point fifth wheel trailers. The leaf springs in the front and rear suspension of the vehicle do not provide adequate load support and may allow the tires to contact the surrounding structure under certain dynamic load conditions.

 

Remedy

Jayco will notify owners, and dealers will install a rubber bump stop into the top sides of the axles, as well as inspect the suspension and replace any defective leaf springs as necessary. Tires with visible damage will be replaced as well. All repairs will be performed free of charge. This recall began July 27, 2020. Owners may contact Jayco customer service at 1-800-517-9137. Jayco’s number for this recall is 9901513.

 

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.

 

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Safety Recall: 20V-385

July 27, 2020

 

IMPORTANT SAFETY RECALL

This Notice Applies to Your Recreational Vehicle 

 

Dear Valued Customer:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

 

Jayco has decided that a defect, which relates to motor vehicle safety, exits in ALL Model Year 2017 North Point fifth wheels.

 

Reason for this recall	Under certain conditions, the suspension system may allow a tire to make contact to the wheel well and surrounding structure of the fifth wheel.  This may cause damage to a tire, premature tire wear and cause handling issues that could lead to increased risk of a crash.
Recall Remedy	Inspection of the suspension to determine the current condition of the leaf springs and bump stop clearance.  Based on the inspection results, replacement of defective leaf springs may be required. ALL units require installation of a bump stop to the top side of each axle directly below the leaf spring hanger tube. (Total of 4).  Tires with visible damage found during inspection and then confirmed as a result of this recall will be replaced as well.
What we need you to do	Please contact an authorized Dealer as soon as possible to schedule an appointment.  The Recall Remedy is free of charge, but could take several days to remedy, depending upon inspection results and parts needed.

 

If you had this repair completed prior to receipt of this recall notice, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall.

If you take your recreational vehicle to your dealer on the agreed service date and the dealer does not remedy this condition on that date or within three (3) days, please contact our Customer Service Department at 800-283-8267.   If you are unable to get this safety defect remedied without charge and/or within a reasonable amount of time after contacting your dealer and Jayco customer service, you may want to contact NHTSA. To submit a written complaint contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153): or go to https://www.safercar.gov..

 

We certainly regret this inconvenience; however, your safety is our most important priority.

 

Sincerely,

Compliance Management

Jayco Towable Products

 

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North Point Suspension Inspection & Bump Stop Installation

Bulletin Type:	Safety Recall	Publication Date:	July 2020
Bulletin #:	20V-385 US 2020-302 Canadian
		Make:	Jayco
Job Code:	9901513
		Model:	North Point FW
Flat Rate(s):	RC024 Inspect Vertical Clearance .2 Hour RC025 Inspect all 4 leaf springs .5 Hour RC026 Replace 4 leaf springs 2.5 Hour RC028 Install 4 bump stops  .7 Hour
		Model Year:	2017

 

Incident:	Inspect North Point Suspension System components for proper load dimensions. If dimensions are out of specification, the leaf springs may require replacement.   NOTE: ALL units require installation of four (4) rubber bump stops.
Affected Units:	ALL 2017 Model Year North Point Fifth Wheels
Parts Kits: 20V-385A Bump Stop 20V-385B Steel Leaf Spring	20V-385A 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   20V-385B  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
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.)

 

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)

 

Step 2: INSPECT LIPPERT STEEL LEAF SPRINGS

STEP 2: PARTS KIT 20V-385B 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 2:

 

• 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 in order to 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 springs.

• 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 springs.

• 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.

 

Step 3 INSTALLATION OF RUBBER BUMP STOPS (4 TOTAL)

STEP 3: PARTS KIT 20V-385A 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

1. The photo above shows the following tools:
2. ½ inch drive Adjustable Torque wrench (zero – 50 Ft/lbs.) (not shown)
3. ½ inch ratchet
4. 3/8 inch ratchet with 16mm socket
5. Punch (approximately 3/8” diameter)
6. Small Sledge hammer
7. 28” long steel straight edge
8. Impact driver with following ½” drive impact sockets: 11/16, 13/16, 14mm, 15mm, 17mm, 19mm
9. Screw gun with 6” long 3/8” nut-setter bit (or standard 3/8” nut-setter bit with 6” bit extension)
10. Drill with a 3/16” drill bit
11. Tape Measure
12. Mechanics Creeper
13. Grease Gun with a tube of Wheel bearing grease Jayco part # 0230435
14. Lippert Manuals:
15. Wet Bolt Installation (part # ccd-0002018)
16. Axle and Suspension Installation (part # ccd-0001412)
17. Trailer Axle Owner Manual 2K-7K

 

REFERENCE SECTION: 

PHOTOGRAPHS FOR STEEL LEAF SPRING KIT & RUBBER BUMP STOP KIT

RUBBER BUMP STOP 20V-385A

Required on ALL Units

 

STEEL LEAF SPRINGS 20V-385B

Required based upon inspection results 

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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.

 

19. Reinstall previously removed tires, wheels and lug nuts (steps 3 and 4) onto the axle (Fig. 3).

A. Start all wheel lug nuts by hand to prevent cross-threading.

B. Continue to hand-tighten wheel lug nuts in the sequential pattern shown in figure 9.

C. After wheel lug nuts are fully hand-tightened, torque nuts in stages and in the sequential pattern shown in figure 9.

 

D. Torque wheel lug nuts to the torque values listed in the Wheel Torque Requirement Chart.

Wheel Torque Requirement Chart
Wheel Size	Stud Size	Torque Sequence
		1 st Stage	2nd Stage	3rd Stage
14″	1/2″	20-25 ft-lbs	50-60 ft-lbs	90-1 20 ft-lbs
1 5″	1/2″	20-25 ft-lbs	50-60 ft-lbs	90-1 20 ft-lbs
16″	1/2″	20-25 ft-lbs	50-60 ft-lbs	90-1 20 ft-lbs
16.5″ x 6.75″	1/2″	20-25 ft-lbs	50-60 ft-lbs	90-1 20 ft-lbs
16″	9/16″	20-25 ft-lbs	60-70 ft-lbs	120-130 ft-lbs
16.5″ x 6.75″	9/16″	20-25 ft-lbs	60-70 ft-lbs	120-130 ft-lbs
16″ Dual and 17.5″ Cone Nut	5/8″	50-60 ft-lbs	100-120 ft-lbs	190-210 ft-lbs
16″ Dual and 1 7.5″ Flange Nut	5/8″	50-60 ft-lbs	1 50-200 ft-lbs	275-325 ft-lbs
14.5″ Demount	1/2″	Tighten sequentially to 85-95 ft-lbs

 

20. The leaf spring replacement procedure is now complete.

 

As a supplier of components to the RV industry, safety, education and customer satisfaction are our primary concerns. Should you have any questions, please do not hesitate to contact us at (574) 537-8900 or by email at customerservice@lcil .com. Self-help tips, technical documents, product videos and a training class schedule are available at lcil .com or by downloading the MyLCI app.

Rev: 12.09.19

CCD-0003592

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TI-124

WET BOLT INSTALLATION

AXLES AND SUSPENSION

 

Recommended Tools:

• Alignment Tool- Spud Wrench or Bull Pin or similar
• Floor Jack
• Grease Gun
• Hammer
• Jack Stands
• Pneumatic Impact Gun w/ 7/16” Impact Socket

*Reference TI-083 for standard chassis blocking*

1. Using jack stands to support chassis, support axle for safe disassembly of axle bolts and After removing axle bolts, inspect spring eyes for brass bushings. Change if needed by using the following procedure:

A. Place brass bushing on an appropriately sized punch. An appropriate sized punch will allow the bushing to slip onto the shaft, but not slide off the other end.

B. Insert end of punch into spring eye.

C. Drive old bushing out with hammer.

D. As the old bushing is driven out, the new bushing will be inserted into the spring eye.

E. The new bushing should be seated as shown (See 1).

 

2. Replace standard mounting hardware, one at a time, with wet bolts and 7/16” locking flange nuts (See Fig. 2). Insert the wet bolts with the grease zerks on the inside of the spring hangers into the axle mounting holes as shown (See Figs. 4 & 5). The serrations under the head of the wet bolt should be fully inserted into the brass bushing.

 

NOTE: Grease hole should be positioned at 3 or 9 o’clock. If the grease holes are not installed properly, the weight of the chassis will prevent the grease from fully lubricating the brass bushings (See Fig. 3 for location of grease hole).

 

Part Numbers:

126197

126238

127846

163692

 

 

3. Tighten locking flange nuts to shoulders of wet bolts. If the serrations under the head of the wet bolt are not fully inserted into the brass bushing, carefully tap the wet bolt into position with a rubber mallet or similar tool. Care should be taken not to damage the grease zerks.

 

4. Apply enough grease to fully lubricate the brass Typically, two squirts from a manual grease gun are sufficient.

 

5. Reconnect electric brakes, if applicable.

 

6. Remount wheels.

 

As a supplier of components to the RV industry, safety, education and customer satisfaction are our primary concerns. Should you have any questions, please do not hesitate to contact us at (574) 537-8900 or by email at customerservice@lci1.com. Self-help tips, technical documents, product videos and a training class schedule are available at lci1.com or by downloading the MyLCI app.

Rev: 08.24.18

CCD-0002018

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
JAYCO	NORTHPOINT	2017

 

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9 Associated Documents

Defect Notice 573 Report

RCLRPT-20V385-2214.PDF 213.396KB

 

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Recall Acknowledgement

RCAK-20V385-6549.pdf 270.626KB

 

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Recall Quarterly Report #3, 2021-1

RCLQRT-20V385-1372.PDF 211.325KB

 

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Recall 573 Report – Amendment 1

RCLRPT-20V385-7504.PDF 213.377KB

 

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Recall Quarterly Report #2, 2020-4

RCLQRT-20V385-1781.PDF 211.241KB

 

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Recall Quarterly Report #1, 2020-3

RCLQRT-20V385-6557.PDF 211.133KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V385-3331.pdf 618.717KB

 

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Remedy Instructions and TSB

RCRIT-20V385-3298.pdf 2631.346KB

 

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Recall Quarterly Report #3, 2021-1

RCLQRT-20V385-1076.PDF 211.325KB

 

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Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V385&docType=RCL

 

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