WORK INSTRUCTIONS
MODEL Z FIFTH WHEEL (ALL EXCEPT Z3610)
SIDEWALL REPLACEMENT
W.I. NUMBER WI-029-2025 Model Z Sidewall Replacement
PRODUCT: Model Z Fifth Wheel (All except Z3610)
DATE: 7/21/25

REVISION: REV-B

LABOR RATE: Per Contract

Applies to:
This document refers to Brinkley Model Z Fifth Wheel Trailers with bedroom slide-outs except Z3610. Refer to
Model G Sidewall Replacement Instructions for Z3610 repairs.
Condition:
Brinkley RV has determined that under certain conditions, minor cracks may form in the sidewalls, typically
originating at the lower corners of a slideout opening.
Correction:
Brinkley RV has established a procedure to replace the sidewall, while providing additional support to
minimize the possibility of future cracks.

Table of Contents
Bedroom Slide-Out Removal Prep w/Wardrobe and Lav (Z2900 and Z3110)........................................................4
Bedroom Slide-Out Removal Prep w/ Bed (All others except 3610)......................................................................7
Removing Bedroom Slide-out from RV.................................................................................................................13
Front Cap Removal...............................................................................................................................................18
Sidewall Fiberglass Skin Removal.........................................................................................................................20
Sidewall Structure Modifications..........................................................................................................................25
Fiberglass Wall Installation...................................................................................................................................32
Reassembly and Prep for Paint.............................................................................................................................42
Wall Structure Diagrams.......................................................................................................................................43
Additional Vendor Technical Information.............................................................................................................47

WARNING
WARNING! Because of the nature of this repair, use of ladders and other climbing and power
equipment is required. Follow all ladder safety instructions posted on ladders and all equipment. It is
required that professional technicians perform the repair, and a team of at least 4 - 5 people be used
for certain parts of this procedure. Failure to do so could result in injury or death.

WARNING
WARNING! Turn off all electrical power to the RV PRIOR to beginning repairs. Be certain the RV is
unplugged from shore power and the batteries are disconnected PRIOR to beginning welding. Failure
to do so could result in property damage and injury or death.

In addition to standard shop tools, the following specialized tools are required:
1.
2.
3.
4.

Tape measure
Chalk line
Screw gun
#2 Square drive bit
(various lengths)
5. Circular saw
6. Jig saw
7. Shop dolly

4

8.
9.
10.
11.
12.
13.
14.

1

2

3

5

Pneumatic (air) saw
Flat bar
Pry bars
Razor knife
Pneumatic caulk gun
3/8” bit
Oscillating multi-tool

7

6

8

10

9

13

12

14

11

15.
16.
17.
18.

7/8” Hole saw
Pin router
Foam gun
Polystick

15

16

17

18

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 1

PARTS INFORMATION
NOTICE: To perform the following sidewall replacement, parts are pre-shipped to your dealership. There
are no kits specific to these repairs; instead, Brinkley has sent sufficient parts to repair a given number of units,
regardless of model or floor plan.
The parts shipment will include the primary and secondary components for this repair including, but not
limited to, sidewall skin, trim, baggage doors, graphics, fascia, etc. Other items will need to be supplied by
your Service Shop, including, but not limited to, cleaners, clean rags, floor coverings, plywood (3/4”X 4’ X 8’),
lumber (2”X 4”, 2”X 6”, various lengths), eight (8) 1/4”X2”X2” angle, in 12’ lengths (Figure 112, page 48) and
miscellaneous shop supplies. Where applicable/possible, this document will call out the appropriate parts for
each given step.
Your service team may also have procedures and equipment in place for some of the steps outlined in this
document (removing a slide-out or front cap for example). Procedures and equipment outlined in this
document are examples, and may deviate somewhat from your established processes and equipment.
Please review the parts received with the packing information to be sure you received everything on the list,
in the appropriate quantities. If there are discrepancies or shortages, please contact your Brinkley Parts
Representative BEFORE commencing repairs.

WARRANTY INFORMATION
ADVANCED CONTACT OR PRIOR AUTHORIZATION REQUIRED
CLAIM REIMBURSEMENT PROCESSING:
All reimbursement requests with completed work orders, including any freight expenses and photographs, should
be submitted via a claim in the Brinkley RV Dealer Portal.
REQUIRED INFORMATION FOR IMMEDIATE REIMBURSEMENT PROCESSING INCLUDES:
1.
2.
3.
4.
5.
6.
7.
8.

The full 17 digit VIN;
The Retail Name if retail sold;
Dealer Name;
Dealer Address;
Dealer Phone Number;
Dealer Hourly Labor Rate;
Work Order detailing the work performed and labor time, and
Photographs of the repair; specifically:
• Existing wall cracks BEFORE starting work
• Aluminum wall sub-structure BEFORE repairs
• Aluminum wall substructure AFTER repairs

Reimbursement checks for claims submitted with all requested information are issued weekly.

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 2

SAFETY
This document provides general instructions. Many variables can change the circumstances of any procedure,
i.e., the degree of difficulty involved in the service operation and the ability level of the individual performing the
operation. This document cannot begin to plot out procedures for every possibility, but will provide the general
instructions for effectively installing, removing or servicing the system. In the event the skill level required is
too advanced or the procedure too difficult, a certified technician should be consulted before performing the
necessary operation. Failure to correctly install, remove or service the system may result in voiding the warranty,
inflicting injury or even causing death.

DANGER
This indicates an imminent hazard that, if not avoided or handled correctly, will result in death or serious
injury.

WARNING
The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause death, serious
personal injury, severe product and/or property damage if not performed safely and within the parameters set
forth in this document.

CAUTION
The “CAUTION” symbol above is a sign that a procedure has a safety risk involved and may cause personal injury,
product and/or property damage if not performed safely and within the parameters set forth in this document.

+ NOTICE
This is used to address best practices that should be utilized and do not commonly result in injury but may
lead to property damage if not careful.

DANGER
DANGER! Removing the slide-out room must be performed in the following
steps to make sure it is removed safely. Read this entire section carefully and
familiarize yourself with the procedure before attempting to remove the slideout room. If additional information is required, refer to the Lippert Slim-Rack
manual (included with but separate from these instructions - QR code on the
right). Failure to follow these directions will result in death or serious injury.

WARNING
WARNING! Turn off all electrical power to the RV PRIOR to beginning repairs. Be certain the RV is
unplugged from shore power and the batteries are disconnected PRIOR to beginning welding. Failure
to do so could result in property damage and injury or death.

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 3

BEDROOM SLIDE-OUT REMOVAL PREP (W/WARDROBE AND LAV - Z2900 - Z3110)
+ NOTICE
NOTICE: The FIRST slide-out section refers ONLY to Model Z2900 and Z3110 floor plans. These are the only
Model Z floor plans with a wardrobe and lavatory sink in the slide-out. If NOT working with a Model Z2900 or
Z3110 and the bedroom slide-out contains a bed, please proceed to page 7 to continue.

WORK INSTRUCTIONS:
1. READ AND UNDERSTAND ALL INSTRUCTIONS PRIOR TO BEGINNING WORK.
2. Cover the bedroom floor in front of the slide-out with protective material to prevent floor covering damage.
3. Remove all personal items from the slide-out wardrobe and bath lav cabinet (Figure 1).

FASCIA

FASCIA

Figure 2a

Figure 1

4. Extend the slide-out approximately half-way to allow access to the back side of the fascia (Figure 2a).
5. Use a screw gun with a #2 square drive bit to remove the screws on the back of the fascia boards (Figure 2b)
6. Use prying tools to remove the wood fascia boards from the metal fascia backer (Figure 2c). NOTE that
there is adhesive in spots to help hold the fascia boards to the fascia backer.
FASCIA
REMOVED

FASCIA
SCREWS

Figure 2b

Figure 2c
WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 4

7. Use a screw gun and a #2 square drive bit to remove the fascia backer from the slide-out (Figure 3).
8. Access the plumbing, 12 VDC and 120 VAC electrical connections beneath the lav cabinet and wardrobe
cabinets (Figure 4a, and 4b).

FASCIA
BACKER
REMOVED

Figure 3

Figure 4a

9. NOTE the colors of the wires and plumbing PRIOR to disconnecting them (Figure 4a and 4b).
10. Locate and identify plumbing and wiring components to be disconnected in preparation for slide-out
removal (Figure 5).
PLUMBING
SPRING

WAGO 12VDC
CONNECTORS
DRAIN
PLUMBING

SLIDEOUT
MOTOR
WIRING

Figure 4b

Figure 5

MOLEX
120VAC
CONNECTOR

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 5

+ NOTICE
Place a bowl or towel under the plumbing to absorb any residual water that may come out when the drain line
is disconnected. Failure to do so may lead to property damage.

11. Disconnect the drain plumbing at the barbed fitting, and the 12VDC wiring at the WAGO connectors
(Figure 6a). Retain the WAGO connectors for future use.
12. Disconnect the fresh water lines at the fittings under the sink (Figure 6b).
DISCONNECT
WATER SUPPLY

DISCONNECT
DRAIN

DISCONNECT
12VDC WIRING

Figure 6b

Figure 6a
13. Disconnect the 120VAC wiring at the Molex connectors (Figure 6c).

14. Pull the loose plumbing and wiring out of the cabinet in preparation to remove the slide-out (Figure 6d).

DISCONNECT
120VAC MOLEX
CONNECTORS

Figure 6c

Figure 6d
15. Proceed to slide-out removal, page 13.

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 6

BEDROOM SLIDE-OUT REMOVAL PREP W/BED - ALL OTHER FLOOR PLANS EXCEPT Z3610)

WARNING
WARNING! Turn off all electrical power to the RV PRIOR to beginning repairs. Be certain the RV is
unplugged from shore power and the batteries are disconnected PRIOR to beginning welding. Failure
to do so could result in property damage and injury or death.
WORK INSTRUCTIONS:
1. READ AND UNDERSTAND ALL INSTRUCTIONS PRIOR TO BEGINNING WORK.
2. Remove all bedding and personal items from the bedroom slide-out area (Figure 1).
3. Remove the mattress from the bed platform and store elsewhere in the RV.(Figure 2).

Figure 2

Figure 1

4. Raise the bed platform to access the support struts below (Figure 3).
5. Disconnect the support struts from their brackets on the platform (Figure 4). Leave the struts attached to the
to bed base.

Figure 3

Figure 4
WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 7

6. Using a screw gun and a #2 square drive bit, remove the screws holding the bed platform to the hinge, and
all of the screws holding the underlayment in place in the slide-out (Figure 5).
7. Remove bed platform and underlayment, and set aside (Figure 6a and 6b).

Figure 6a

Figure 5
8. Remove the drawers from the bed base and set aside (Figure 7).
9. Tape the bed struts in place and drawer openings to hold the drawer guides in place (Figure 8).

Figure 6b

Figure 7

Figure 8
WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 8

10. Access wiring in slide-out; label or photograph for re-installation, and carefully disconnect wiring (Figures
9a, 9b, 9c, and 9d). Retain Wago and Molex connectors for later installation reconnection.

Figure 9a

Figure 9b

Figure 9c

Figure 9d

11. Using a screw gun and a #2 square drive bit, remove the end panels where the vent and recepticals were
located (Figure 10).
REMOVE
PANEL

REMOVE
PANEL

Figure 10
WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 9

12. Cover the bedroom floor at the end of the bed base
with carpet or cardboard to protect the linoleum
during the next steps. (Figure 11) .

FLOOR
COVERING

13. Remove all of the fasteners holding the bed frame
to the slide-out (Figures 12a, 12b, and 12c).

Figure 12a

Figure 11

Figure 12b

Figure 12c

14. Once all fasteners are loose or removed, rotate the bed frame slowly out of the slide-out and stand it on end
in the bedroom (Figures 13a, 13b, 13c and 13d) on the floor covering previously installed. Use caution not to
hit the ceiling or air coditioner during this process.
SLIDEOUT
STRUCTURE

BED FRAME

Figure 13a

Figure 13b

Figure 13c

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 10

Figure 13d

15. Retract the bedroom slide to a position where it is approximately halfway in (Figure 14) to access the back
side of the fascias.
16. Using a screw gun and #2 square drive bit, locate and remove the screws located on the back side of the
fascia panels (Figure 15).
SLIDEOUT

FASCIA

RETRACT HALF WAY

FASCIA
BACKER

Figure 14

SCREWS

Figure 15

WI-029 Sidewall Replacement REV-B
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 11

17. Pull the side fascias off by pulling out from the bottom of the fascia first (Figure 16), then pulling down to
disengage the biscuit joint where the side fascia meets the top fascia (Figure 17). Note that there are spot
applications of CHEM-X adhesive on the backs of the fascia boards, so it may require a prying tool to
remove them from the backers. Where possible, retain original fascia boards for later reuse.
BISCUIT

Figure 16

Figure 17

18. The top fascia has a channel on the backside of it
that hooks over the top of the backplate. Pull out
from the bottom first and then push up to pop the
fascia off the backplate (Figure 18). If not damaged
during removal, set fascia boards aside for later use.
It damaged during removal, replace damaged fascia
boards with provided parts (not shown).