WORK INSTRUCTIONS
MODEL G FIFTH WHEEL
SIDEWALL REPLACEMENT
WI: WI-014-2025 Model G and Z3610 Sidewall Repair Instructions
PRODUCT: Model G Fifth Wheel
DATE: 7/21/2025

REVISION: REV-D
LABOR RATE: Per Contract

Applies to:
This document refers to Brinkley Model G Fifth Wheel Trailers.
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 and Modification......................................................................................................4
Front Cap Removal...............................................................................................................................................26
Sidewall Fiberglass Skin Removal.........................................................................................................................28
Sidewall Structure Modifications..........................................................................................................................33
Fiberglass Wall Installation...................................................................................................................................44
Reassembly and Prep for Paint.............................................................................................................................50
Wall Structure Diagrams.......................................................................................................................................52
Additional Vendor Technical Information.............................................................................................................55

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
90 Degree drill
adapter
#2 Square drive bit
(various lengths)
Wire cutters
Circular saw (w/sharp
blade)
Jig saw (w/sharp
blade)

5.
6.
7.
8.

1

2

3

4

5
6

9. Hand grinder
10. Hand-held pneumatic
reciprocating saw
11. 1/4” Drill bit
12. Flat bar
13. Pry bars
14. Razor knife
15. Pneumatic caulk gun
16. 3/8” spade bit
17. Oscillating multi-tool

18.
19.
20.
21.
22.
23.

Weld blanket
7/8” Hole saw
Ratchet strap
Foam gun
Polystick
Trowel

21
19

20

13

17

16

15

9

12

11

10

14

8

7

18

22

23

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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.

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
Page 3

BEDROOM SLIDE-OUT REMOVAL

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 1

Figure 2

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-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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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
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Product: Model G Fifth Wheel
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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 recepts were located
(Figure 10).
REMOVE
PANEL

REMOVE
PANEL

Figure 10
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Product: Model G Fifth Wheel
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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 conditioner during this process.

Figure 13a

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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SLIDEOUT
STRUCTURE

BED FRAME

Figure 13b

Figure 13c

Figure 13d

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Product: Model G Fifth Wheel
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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

SCREWS

Figure 14

Figure 15

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

WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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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).
UPPER
FASCIA

Figure 18
19. Using a screw gun and a #2 square drive bit, remove the fasteners holding the backer plates on the slide-out
(Figures 19a and 19b). Remove the 5 individual backer plates used. The bottom corner pieces have longer
screws than the rest of the plates. Retain plates and fasteners for later use.
20. Remove the T-Bracket from the exterior slide-out fascia (Figures 19c and 19d).
BACKING
PLATE

Figure 19a

Figure 19b

T-BRACKET

T-BRACKET

Figure 19c

Figure 19d
WI-014-2025 Sidewall Replacement Rev-D
Product: Model G Fifth Wheel
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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.

21. Extend the room until it is a couple of inches short of full extension (to allow full access to the slide-out
mechanism columns). DO NOT EXTEND FULLY!
22. Using a screw gun and a #2 square drive bit, remove all of the column screws (Figure 21a, 21b, 21c, and
21d). including the four (4) screws hidden behind the bulb seal on each side of the slide-out (Figure 21e and
21f, next page).
Figure 21a

Figure 21b

COLUMN
COLUMN

Figure 21c

COLUMN

Figure 21d

COLUMN

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Product: Model G Fifth Wheel
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BULB
SEAL

BULB
SEAL

HIDDEN
SCREW
HIDDEN
SCREW

Figure 21e

Figure 21f

23. Pull the interior portion of the column and wipe seal away from the wall. Disconnect the motor wire
connector (Figure 22a) and feed the motor end of the connector through the hole in the wipe seal (Figure
22b).
24. Use a screw gun and a #2 square drive bit to remove wire clamp from slide floor (Figure 23). Repeat steps 23
and 24 on both sides.

SLIDEOUT
MOTOR WIRE
CONNECTOR

SLIDEOUT
MOTOR WIRE
CONNECTOR

Figure 22a

Figure 22b

SLIDEOUT
MOTOR WIRE
FASTENER

Figure 23
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Product: Model G Fifth Wheel
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WARNING
WARNING: The next steps involve removing and moving the bedroom slide-out from the RV. Extreme caution
should be observed during this process to make sure the slide-out is properly braced and supported to prevent
it from falling. Failure to do so 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. Approximate weight of the slide-out
room is 400 lbs.

25. Place lifting and support equipment under the slide-out room (Figure 24). Examples shown in photos use
a forklift with a (approximately) 70” X 30” X 6” platform built from 2”X6” boards to support and move the
room from below (Figure 25). When the platform is in place below the slide-out room, extend the room fully.

Figure 24

Figure 25

26. Use the lifting device to lift the room gently in the opening to take the weight off side-out drive mechanism
in preparation for removal. Be certain the slide-out box is secure and will not shift or move unexpectedly.
NOTE the slide-out in the unit is now being held in place by the exterior seals and vertical columns (not
shown).
27. Once the room is safely and properly secured, use a razor knife to cut the TOP wipe seal at both ends to
separate it from the side wipe seals (Figure 26a and 26b).

Figure 26a

Figure 26b
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Product: Model G Fifth Wheel
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28. Using a screw gun with a #2 square drive bit, remove screws from the outside of the slide mechanism column
(Figure 27).
29. Use a razor knife to cut the sealant away between the vertical columns and the sidewall (Figure 28), while
using a prying tool to pry the vertical columns away from the sidewalls (Figure 29a and 29b).

Figure 27

Figure 29a

Figure 28

Figure 29b
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Product: Model G Fifth Wheel
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30. Prepare two wooden supports from 2”x 6” boards, approximately 4’ x 6” x 6” on the floor to rest the slide-out
box on, and cover top surfaces with styrofoam (or other soft material) to prevent damage to the exterior face
of the slide-out (Figure 30).
31. Remove the slide-out from the RV and place it on the floor, then rotate the slide-out room face down onto
the supports (Figure 31).

4’X6”X6”
SUPPORTS

Figure 30

Figure 31

32. Remove the slide-out columns from the sides of the slide-out room (Figure 32) by sliding them out of
their mounting brackets. NOTE that there is a small plastic rivet that will break while trying to remove the
columns; this can be replaced during re-installation with another plastic rivet or a screw (not provided).
+ IMPORTANT
If the unit being worked on is VIN 001091 or higher, skip now to “FRONT CAP REMOVAL” on page 26.

33. Using a screw gun and a #2 square drive bit, remove the fasteners holding the L-shaped bottom slide corners
from the slide-out box (Figure 33).