P/N 100904

Figure 59a
ALUMINUM
SIDEWALL
STRUCTURE

Figure 59d
SIDEWALL/ROOF CROSS SECTION

Figure 59b
FASTEN BELOW FLOOR LINE

FIBERGLASS
SIDEWALL
ALUMINUM
SIDEWALL
STRUCTURE

FLOOR

Figure 59c

2-1/2” WOOD SCREW
P/N 100904

Figure 59e
SIDEWALL/FLOOR CROSS SECTION
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 48

4. Once the new fiberglass is secure around the perimeter of the wall structure, use a hand held power saw or
router to begin routing or cutting off the overlap areas (front cap area, baggage doors, etc.) (Figures 60a, and
60b), Route out the slide-out opening and any window openings in the fiberglass (Figure 60c).

Figure 60a

Figure 60b

Figure 60c

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 49

+ NOTICE
NOTICE: It is often easier to hang the plywood covers if they are cut for the front angled section of the
sidewall where the front cap attaches, as well as where the storage compartment doors are located.
5. Using a screw gun and #2 square drive bit, install the felt covered plywood panels over the fiberglass using
2-1/2” wood screws (P/N 100904) (Figures 61a and 61b). Secure them at the top into the roof sill, and at the
bottom into the exposed structure BELOW the sidewall.

Figure 61a

Figure 61b

6. Use a screw gun with a #2 square drive bit to secure the L-brackets over the plywood panels using 3” #10
wood screws (P/N 104187) (Figure 62a). Use two (2) L-brackets to secure the panels as shown (Figure 62a).
Secure at the top and bottom.
7. Use clamps to secure the openings for the slide-out, basement doors, and the front cap area (Figures 62b and
Page 49, Figure 65). Where possible, place clamps at a minumum of 12” apart, closer where applicable.
TWO (2)
L-BRACKETS

Figure 62a

Figure 62b
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 50

8. Once the front alcove is clear of excess fiberglass, attach the bottom of the front L-bracket to the pin box with
a ratchet strap and pull it tight to compress the sidewall in that area (Figure 63).

L-BRACKET

PIN BOX

RATCHET
STRAP

9. Insert shims between the L-brackets and plywood panels
to provide additional pressure on the sidewall to further
activate the adhesive (Figure 64a and 64b).

Figure 64a

Figure 63
SHIM

Figure 64b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 51

+ NOTICE
The cure time for the supplied adhesive is 24 hours. DO NOT remove bracing until cure time has passed.
DOUBLED
L-BRACKETS

FIBERGLASS INSTALLED,
CLAMPED, BRACED AND
SHIMMED FOR CURING
(FIGURE 65)

DOUBLED
L-BRACKETS

CLAMPS
CLAMPS

Figure 65
REASSEMBLY AND PREP FOR PAINT
1. Once the adhesive has had sufficient
time to cure, remove all of the
L-brackets and plywood bracing
from the side of the RV (not
shown).

LI

RE

UT

C
EF

Figure 66a

Figure 66b

2. Using a hand held mini-saw, make a vertical relief cut
at the front lower corner of the slide-out opening. Cut
3/16” deep to ensure ONLY the skin and backer are cut
(full material depth is approximately 0.250” or 6.35mm)
DO NOT cut into the metal sidewall structure under the
skin. (Figure 66a and 66b).

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 52

REASSEMBLY AND PREP FOR PAINT (CONT’D)
3. In preparation for fiberglass work and final application of paint and graphics, the following steps need to
be performed. Refer to the prior removal instructions if there are questions about fit, measurements or
fasteners.
•

Installation of the front cap - connect all wiring, then tuck the roof membrane along the back edge and
sides of the cap prior to securing the cap in place. Install trim and seals prior to paint.

•

The roof membrane can be rolled over onto the sidewall, but should not be secured. DO NOT install the
roof rail at this time. The roof rail must be loose for paint and fiberglass work, and is to be installed after
the unit is painted.

•

Installation of the bedroom slide-out - all interior and exterior components of the bedroom slide-out
should be installed, adjusted, and working properly when the unit goes to paint. The room should
operate as normal, traveling completely in and out when sent to paint.

•

Installation of cargo and appliance doors - these should be secure, adjusted for proper operation and
locking, sealed, and ready for paint prior to sending to the paint shop.

WARNING
WARNING - Before installing the shore power cord input connector, make sure the RV is unplugged from ALL
power sources (including shore power) and all disconnects are turned “OFF”. Failure to do so can result in death,
serious personal injury, severe product and/or property damage.

1. Install the shore power cord receptical:
•

Access the original mounting hole in the structure behind the new skin (Figure 67a). Use a screw gun
with 3/16” drill bit to drill a hole in the new sidewall skin where the original hole is in the structure
(Figure 67b).

•

On the OUTSIDE of the new skin, use a hand held router inserted in the previously drilled 3/16” hole to
route out the opening for the shore power cord connector (Figure 68).

ORIGINAL HOLE

NEW SIDEWALL

Figure 67a
VIEW FROM INSIDE

DRILL FROM INSIDE-OUT
THROUGH SIDEWALL

Figure 67b

ROUTE OUT HOLE

Figure 68

VIEW FROM OUTSIDE

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 53

•

Access the electrical cord and pass it through
the new opening (Figure 69).

•

Remove the caps covering the ends of the
wires. Insert the wires into the appropriate
color coded holes in the shore power cord
input connector (Figure 70a). BE CERTAIN
the wires are properly seated and positioned
as illustrated (Figure 70b).

Figure 69

Figure 70a

INSULATION ON WIRING SHOULD BE STRIPPED
BACK 3/4” FROM THE END OF THE WIRE, AND
COPPER SHOULD BE BOTTOMED OUT IN THE
LUG. THE INSULATION SHOULD EXTEND BELOW
THE TOP EDGE OF THE LUG HOLE, BUT MUST
NOT EXTEND INTO THE TERMINAL.

NO EXPOSED STRANDS
ABOVE THIS LINE
NO INSULATION
BELOW THIS LINE

EXPOSED STRANDS
INSIDE HOLE

Figure 70b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 54

•

Once satisfied all connections are correct and input connection housing is undamaged, use a torquing
tool (that measures in in-lbs.) and a #2 square drive bit to torque ALL CONNECTIONS to the
appropriate torque for the style of inlet used (Figure 71a and 71b):
h Furrion: 25 in-lbs. - Flat Head bit
h Epicord: 35 in-lbs. - Flat Heat, Phillips Head or Square Drive bit
h Epicord: 75 in-lbs. (units produced AFTER 1/1/2026). Square Drive bit
h See Figures 72a and 72b for differences.

Figure 71a

Figure 71b

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 55

+ NOTICE
NOTICE: The following steps involve installing the two (2) different shore power cord connector wiring covers
Brinkley uses: installation and removal are virutally identical, but there are slight differences in the way the
back covers are attached that affect how you reinstall them over the wire connections.
•

The Furrion connector uses two screws that pass though the front connection opening to hold the rear
wiring cover in place (Figure 72a). Install the rear cover over the wires and seat it again to the back of the
connector base. Use a HAND SCREWDRIVER with a #1 Phillips bit to install the two screws through the
front of the connector base to secure the wiring cover. Install and hand tighten the plastic nut to snug into
the wiring cover.

•

The Epicord connector uses a “twist-lock” action to lock the rear wiring cover to the back of the connector
base (Figure 72b). Slide the rear wiring cover down over the wires and against the back of the connector
base. Twist the rear wiring cover clockwise to lock into the base. Install the compression cap onto the rear
wiring cover and twist it clockwise until snug to seal off the wiring inside the rear wiring cover. NOTE that
Epicord connectors BEFORE 1/1/2026 also use two small screws passing through the connector base to
further lock the rear wire cover in place (just as with the Furrion connector).
PLASTIC NUT

REAR WIRING
COVER

COMPRESSION
CAP

REAR WIRING
COVER

LOCKING TAB
CONNECTOR
BASE

Figure 72a
FURRION CONNECTOR

Figure 72b
EPICORD CONNECTOR
WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 56

•

Install the wire cover onto the shore power cord input receptical. Where applicable, use a hand held
flat head scew driver to secure the wire cover to the shore power cord connector base with the original
screws (Furrion Figure 72a and 72b / Epicord Figure 72b - page 56).

•

Install the shore power input connector into the new hole in the sidewall (Figure 73a) using a screw gun
with a #2 square drive bit and the four (4) original fasteners (Figure 73b).

INSE

RT

Figure 73a

Figure 73b

4. Perform final body and paint work. Repair any defects in fiberglass, screw holes, and sealant prior to
painting.
5. Install graphics as necessary.
6. Final inspection, leak test and detailed review of body work, paint and exterior sealants.
7. lnstallation complete. File claim through Brinkley Dealer Portal or through Brinkley Customer Care
Department at [email protected].

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 57

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 58

RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

Z2900 STRUCTURE COLOR KEY

Z2900 WALL
STRUCTURE

X

ADD STRUCTURE

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 59

RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

Z3100 STRUCTURE COLOR KEY

Z3100 WALL
STRUCTURE

X

ADD STRUCTURE

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 60

RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

Z3100 STRUCTURE COLOR KEY

Z3110 WALL
STRUCTURE

X

ADD STRUCTURE

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 61

RED

YELLOW

WHITE

COLOR
X

X

EXISTING STRUCTURE ADD IF NOT THERE

Z3100 STRUCTURE COLOR KEY

Z3400 WALL
STRUCTURE

X

ADD STRUCTURE

ADDITIONAL VENDOR INFORMATION ACCESS
Additional information is available on various systems and components you may encounter while performing
the repairs in this document. The QR codes listed below provide links to the various manufacturer’s service
and/or installation information. If there is a discrepancy between the instructions provided by Brinkley in
this document and the component manufacturers information, default to the component manufacturers
instructions.
If you have additional questions, please contact Brinkley Customer Care at 888-502-3460, or 574-501-4280,
Mon-Fri, 8AM to 5 PM EST, or email: “[email protected]”.
Lippert Slim-Rack Slide-Out
Progamming, Installation and
Service Manual

Installation and
Service Instructions

KORAPUR urethane adhesive
sealant (Brinkley P/N 112154)
Adhesive Information

General
Information

Safety Data Sheet

EternaBond MicroSealant
Tape (Brinkley P/N 102489)

Information

Installation
Instructions

Safety Data Sheet

WI-029 Sidewall Replacement REV-F
Product: Model Z Fifth Wheel (ALL Except Z3610)
Page 62