January 26, 2024

Service Bulletin #SB035

Subject: Bolt-On Ratchet Bushing Kit on 2-Car Delivery Units
Models Affected: 2CarDU and 2CarDUXL

Instructions:
1. Identify 2-Car Unit(s) from attached VIN list.
2. Identify units from the list that were built before April of 2022
which have not yet had the Cam Plate replaced, as shown in
drawing #04598 (from prior bulletin, enclosed again here for
reference).
3. If the work will be performed at an authorized warranty repair
facility or other repair facility versus at Cottrell’s service center in
Gainesville, Georgia, please send a written request to Cottrell via
email at [email protected] for the repair kit(s) to be
shipped to the repair location you have selected. Please reference
#SB035 and identify the VIN(s) in your email.
4. For units that have not already had the Cam Plate replaced, please
make the necessary replacement of the Cam Plate using drawing
#04598 first, and then proceed with ratchet shaft repairs as set forth
below.
5. Please perform the ratchet shaft repairs referenced on attached
drawing #05387. If additional instructions for disassembling the
ratchet shafts are needed, please refer back to drawing #04598.
6. Submit invoice for labor (6 hours maximum) via email to Cottrell at
[email protected] for reimbursement. Please reference
#SB035, the VIN(s) and payment information for reimbursement.

2125 Candler Road, Gainesville, Georgia 30507
www.cottrelltrailers.com; 1-800-827-0132

RATCHET TROUBLESHOOTING/INSTALLATION GUIDE
2-CAR DELIVERY UNITS MANUFACTURED BY COTTRELL, INC.
IF RATCHET SHAFT DOES NOT SPIN FREELY BY HAND IN THE LOCKED (ONE DIRECTION)
AND UNLOCKED (BOTH DIRECTIONS) POSITIONS, FOLLOW THIS CHECKLIST:

KIT 171124 INCLUDES:
1 X 171078 CAM PLATE
1 X 6353 5/8 FLATWASHER
2 X 09168 1/4" ROLL PIN
3 X 153285 SQUARE WASHER

UPPER DECK POSITIONS:
CHECK THE INTERIOR ROLL PIN (UPPER DECK LOCATIONS ONLY)
A. IF THE ROLL PIN IS TIGHT AGAINST THE WELDED BUSHING AND
CAUSING FRICTION, KEEPING THE SHAFT FROM FREELY ROTATING:
1. REMOVE THE INNER ROLL PIN
2. REMOVE THE OUTSIDE CAM PLATE (SEE LOWER DECK POSITION DIRECTIONS BELOW)
3. SLIDE THE RATCHET SHAFT OUT FAR ENOUGH TO REMOVE THE STRAP RETAINER
4. ADD A SQUARE WASHER (153285) TO THE SHAFT, REINSTALL THE STRAP RETAINER
5. INSTALL THE NEW CAM PLATE (171078) (SEE CAM PLATE REPLACEMENT DIRECTIONS)
6. DRILL A NEW CENTERED HOLE 90° FROM EXISTING HOLE FURTHER INWARD ON THE SHAFT
ALLOWING SPACE BETWEEN THE HOLE AND THE NEWLY ADDED WASHER, SUCH THAT ROLL
PIN IS NOT TIGHT AGAINST THE WASHER. IF THERE IS ALREADY A HOLE THROUGH THE ADJACENT
FACE, ADD THE ADDITIONAL PROVIDED WASHERS TO THE SHAFT BEFORE DRILLING A NEW ROLL PIN HOLE
7. INSTALL THE PROVIDED REPLACEMENT ROLL PIN (09168) (SHOULD BE PRESS FIT)
B. IF THE ROLL PIN IS NOT TIGHT AGAINST THE WELDED BUSHING, FOLLOW THE CAM PLATE REPLACEMENT
INSTRUCTIONS BELOW

STRAP RETAINER

ADD 153285
SQUARE WASHER
REMOVE AND DISCARD
ORIGINAL ROLL PIN
CAM PLATE REPLACEMENT: REMOVE AND REPLACE THE CAM UNLOCK
PLATE WITH THE UPDATED VERSION (171078) AS SHOWN BELOW:

DISCARD
SAVE ALL COMPONENTS
EXCEPT CAM PLATE

171078
6353

INSTALLED ON INTERIOR

NEW CAM PLATE AND ADDITIONAL
WASHER PROVIDED IN KIT

IMPORTANT: WHILE DISASSEMBLED, CHECK THE FIT OF THE RATCHET GEAR TO THE RATCHET SHAFT.
THIS SHOULD NOT BE A PRESS FIT. IF THERE IS NO MOVEMENT POSSIBLE IN THE GEAR, SEE PAGE TWO FOR
DEBURRING INSTRUCTIONS.

DOC04598

RATCHET TROUBLESHOOTING/INSTALLATION GUIDE
2-CAR DELIVERY UNITS MANUFACTURED BY COTTRELL, INC.
IF THE GEAR APPEARS TO BE FIXED IN PLACE AS IF IT WERE PRESS FIT:
1. SLIDE THE GEAR BACK ON THE RATCHET SHAFT FAR ENOUGH TO REMOVE THE ROLL PIN
2. REMOVE AND DISCARD THE OUTER ROLL PIN
3. REMOVE GEAR FROM RATCHET SHAFT
4. BUFF THE HIGHLIGHTED AREA THE GEAR SITS TO REMOVE BURRS AND PREVENT A PRESS FIT
5. REINSTALL GEAR ON RATCHET SHAFT
6. INSTALL THE PROVIDED ROLL PIN (09168)
7. REINSERT THE RATCHET SHAFT INTO THE RATCHET BOX
8. CONTINUE WITH THE NEW CAM PLATE INSTALLATION INSTRUCTIONS

PARTS REFERENCE:
(ADD "A" FOR OPPOSITE HAND ON PAWL AND SPRING PART NUMBERS)
09168

6267
153285

6260
153700
171078
6363
6260

6353
153701

6235

153686 (153686A)
153010 (153010A)
6353
6343

DOC04598

RATCHET TROUBLESHOOTING/INSTALLATION GUIDE
2-CAR DELIVERY UNITS MANUFACTURED BY COTTRELL, INC.
KIT 171124 INCLUDES THE FOLLOWING:
1 X PART NUMBER 6353
5/8 FLATWASHER GRADE 8 YELLOW ZINC - .079 THICK

2 X PART NUMBER 09168
ROLL PIN 1/4 DIA. X 1-3/4 LONG

3 X PART NUMBER 153285
SQUARE WASHER

1 X PART NUMBER 171078
OUTSIDE CAM UNLOCK PLATE - ZINC PLATED

BOLT-ON RATCHET BUSHING KIT INSTALLATION
GUIDE
2-CAR DELIVERY UNITS MANUFACTURED BY COTTRELL, INC.
KIT 178633 FOR DU TRUCKS INCLUDES:

KIT 178634 FOR DU XL TRUCKS INCLUDES:

8 X 153287 SQUARE RATCHET SHAFT
4 X 178262 LIFT DECK BRACKET
2 X 178555 FRONT LOWER DECK BRACKET
2 X 178527 REAR LOWER DECK BRACKET
28 X 6225 3/8-16 X 1 1/2 GRADE 8 HEX CAP SCREW
56 X 6260 3/8 GRADE 8 FLATWASHER
28 X 6267 3/8-16 GRADE 8 STOVER LOCKNUT

4 X 153287 SQUARE RATCHET SHAFT (SHORT)
4 X 171552 SQUARE RATCHET SHAFT (LONG)
4 X 178262 LIFT DECK BRACKET
2 X 178555 FRONT LOWER DECK BRACKET
2 X 178527 REAR LOWER DECK BRACKET
28 X 6225 3/8-16 X 1 1/2 GRADE 8 HEX CAP SCREW
56 X 6260 3/8 GRADE 8 FLATWASHER
28 X 6267 3/8-16 GRADE 8 STOVER LOCKNUT

AS NECESSARY, REFERENCE DOCUMENT 04598 FOR INSTRUCTIONS REGARDING DISASSEMBLY
AND REASSEMBLY OF THE AFFECTED LOCATIONS SUFFICIENT TO INSTALL THE APPROPRIATE
BUSHING BRACKETS.

LIFT DECK LOCATIONS (4):
1. DRILL OUT THE CENTER OF EACH HUCK HEAD TO REMOVE THE EXISTING BRACKET
2. ENSURE THAT THE RATCHET SHAFT IS FREE-SPINNING IN THE BUSHING AND REINSTALL THE NEW
BRACKET (178262) WITH THE PROVIDED 3/8 HARDWARE (BOLTHEAD ON TOP OF THE TRACK AND
ONE WASHER AGAINST THE BOLTHEAD AND ANOTHER AGAINST THE LOCKNUT)

DOC05387

LOWER DECK FRONT LOCATIONS (2):
1. DRILL OUT THE CENTER OF EACH HUCK HEAD TO REMOVE THE EXISTING BRACKET
2. REINSTALL THE NEW LIFT DECK BRACKETS (178555) WITH THE PROVIDED 3/8 HARDWARE
(BOLTHEAD TO THE OUTSIDE OF THE UNIT AND ONE WASHER AGAINST THE BOLTHEAD AND
ANOTHER AGAINST THE LOCKNUT)

LOWER DECK REAR LOCATIONS (2):
1. INSTALL THE NEW BRACKET (178527) ON THE RATCHET SHAFT AND REINSTALL THE RATCHET
COMPONENTS
2. WITH THE NEW BRACKET AS CLOSE TO THE WALL OF THE RATCHET POCKET AS POSSIBLE AND THE
RATCHET SHAFT FREE-SPINNING IN THE BUSHING, MARK THE HOLES OF THE BRACKET ONTO THE
STEEL TRACK
3. MOVE THE BRACKET OUT OF THE WAY AND DRILL FOUR 7/16” HOLES IN THE TRACK PER BRACKET
4. INSTALL THE BRACKETS WITH THE PROVIDED 3/8” HARDWARE (BOLTHEAD ON TOP OF THE TRACK
AND ONE WASHER AGAINST THE BOLTHEAD AND ANOTHER AGAINST THE LOCKNUT)

DOC05387