THULE® AWNING SPRING
ARM REPLACEMENT

AWNING

mL

TO 4900 - TO 5102 - TO 5200 - TO 8000
TO 8000 - TRISTOR2 - TO 5003

VuiPPERT

Installation must be performed by a qualified installer, service agency, manufacturer or dealer.

Manufactured for V CiPPERT

Lippert provides this and other Thule product manuals for download at
https://support.Ici1.com/thule-awnings.

Rev: 04.21.2025 CCD-0008884

THULE® AWNING SPRING
ARM REPLACEMENT

AWNING

VuiPPERT

Purpose

This document outlines the procedure to replace the Thule® Spring Arm.
Safety

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

This TI provides general instructions. Many variables can change the circumstances of the instructions, i.e.,
the degree of difficulty, operation and ability of the individual performing the instructions. This document
cannot plot out instructions for every possibility, but can provide general instructions for effectively
interfacing with the device, product, or system. Failure to correctly follow the provided instructions may
result in death, serious personal injury, severe product and/or property damage, including voiding of the
Lippert limited warranty.

Failure to follow instructions provided in this manual may result in death, serious personal injury
and/or severe product and property damage, including voiding of the component warranty.

Always wear eye protection when performing service or maintenance to the coach. Other safety
equipment to consider includes hearing protection, gloves and possibly a full face shield, depending
on the nature of the service.

Arms are under a great deal of tension. NEVER attempt to remove or service the arms of the awning
without first securing them with heavy-duty zip ties, hook and loops, or ratchet straps.

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

Make sure the roll tube is adequately supported before removing the support arm assembly. Failure to
do so may result in serious personal injury or property damage.

Spring Tension Warning Reminder

This symbol is to remind the user that arms are under a great deal

=. of tension and should always be secured while performing any kind
of service or maintenance on the awning. Failure to secure the arms
may result in property damage or serious personal injury.

S/,

Rev: 04.21.2025 CCD-0008884

7 THULE® AWNING SPRING
OLiPPERT ARM REPLACEMENT

AWNING

Resources Required

+ Cordless or electric drill or screw gun + Measuring tape
+ Appropriate drive bits + Non-permanent marking utensil

+ %" (13mm)socket wrench + Allen Wrench
Procedure

1. Extend the awning away from the awning's main
housing. Extend a maximum of 2 feet (Fig. 1).

2. Loosen the screws of the fabric (Fig. 2).

Secure the Spring Arm with a heavy-duty zip tie (Fig.
3A) or wrap heavy duty hook and loop (Fig.3B) around
the arms to ensure that the arms don't come open.
Then tape the zip tie or hook and loop in place for
safety so that it doesn't slide off the Spring Arm.

Remove the screw from the main housing end cap and
gently pull the end cap off the main housing (Fig. 4).

Main housing

Rev: 04.21.2025 CCD-0008884

7 THULE® AWNING SPRING
OLiPPERT ARM REPLACEMENT

AWNING

5. Remove the three screws on the inside of the inner
end plate, and remove inner end plate (Fig. 5).

6. Remove the nut end cap cover that is
over the two bolts (Fig. 6).

Nut end cap cover

Remove the screw on the back side of .

the end plate on the lead rail housing Lead rail end cap
(Fig.7). cover \\J
Remove the lead rail end cap cover from
the end plate (Fig. 7).

Lead rail
housing

Mark the end of the Spring Arm on the case
where the nuts are, with a pencil to ensure it's in
the right position when the new Spring Arm is
installed (Fig. 8).

Mark here

Rev: 04.21.2025 CCD-0008884

7 THULE® AWNING SPRING
OLiPPERT ARM REPLACEMENT

AWNING

Mark the nut placement, with a pencil, on the lead
rail housing (Fig. 9).

Loosen and remove the two bolts, facing you, on
the Spring Arm in the main housing (Fig.10).

Loosen and remove the nut and washer on the lead
rail housing (Fig. 11).

Slide the Spring Arm out of the main housing and
the lead rail housing at the same time.

Slide the new Spring Arm into the main housing
and lead rail housing at the same time.

Slide them in so that the edges of the nut and
washer on the new Spring Arm on the lead rail
housing, and the edge of the new Spring Arm main
housing lines up with the previously marked pencil
marks (Fig.8 and Fig. 9).

Make sure to insert the clam proof support into the
main housing under the Spring Arm (Fig. 12). If not
inserted, the Spring Arm will not stay in place.

support

N
Main housing

Rev: 04.21.2025 CCD-0008884

7 THULE® AWNING SPRING
OLiPPERT ARM REPLACEMENT

AWNING

+ Tighten down both of the bolts on the main
housing and the nut on the lead rail housing
(Fig.10 and Fig. 11).

Lift the inner end of the Spring Arm (towards the
fabric) and apply a Round Loop Coin to protect
the fabric (Fig. 13).

Spring arm

Fasten the screws of the fabric (Fig.14).

If applicable, adjust the Spring Arm to the correct
height and pitch.

For height adjustment: Use a ¥2" (13mm) socket
wrench (Fig.15A), tighten one or both of the nuts on
the end (Fig.15B) of the Spring Arm.

For pitch adjustment: Use an Allen wrench to adjust
the Allen head screw (Fig.15C).

Follow steps 18 through 20 until the following are
accomplished (Fig.15):

. Spring Arms MUST fold straight into the main
housing. Oo;
Awning MUST be horizontally level and slope
down when it is open.

Test Awning and adjust, if needed.
Main housing MUST close completely.
Lead rail MUST close straight into main housing.

Spring ay

Reverse steps 7 - 3 to replace the covers and end caps.
Run the awning in and then all the way out to ensure that it works correctly.

Rev: 04.21.2025 CCD-0008884