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720Deere's avatar
720Deere
Explorer
May 15, 2013

Happy Jack Bed Failure

I have read previous posts about the top bunk sagging on the Happy Jack beds in the garage and sure enough mine appeared pretty weak when we did our pre-delivery inspection last October. Even with no more than a 100 lb child in the bed, the front frame would sag pretty bad. I finally took the Fuzion in for some minor warranty work about 7 weeks ago with the bed being one of my complaints. Overall it took the dealer 4 attempts to get Keystone to offer an acceptable fix, but thanks to their persistence, Keystone finally authorized them to install a new top bed.

I fully expected Keystone to say there is nothing abnormal about the bed (which they did twice) and the dealer to simply pass that info on. If it hadn't been for the service writer refusing to accept anything less than a structural repair, I would be repairing the bed myself. I had heard of several cases that were denied repair. I think the final straw was when they used a 200 lb man to demonstrate how weak the bed was and then while taking pictures of the same man in the bed of a new trailer sitting on the lot to show that it reacted nearly the same, the "new" bed frame made cracking sounds and sagged worse. Warranty claim success truly does lie in the hands of the dealer service department.

If you experience the same problem with your Happy Jack bed system on any brand toyhauler, don't take no for an answer. Insist that your dealer persist until the manufacturer does the right thing. As much as people seem to harsh on Camping World dealers, I am proud to say that my dealer recently joined the Camping World network and I am glad to have them on my side.
  • Ts1 wrote:
    I repaired my own in our fuzion. With help of a friend, removed bed, removed million staples, layed a sheet of 3/8 sanded plywood and screwed together. Restapled materiel and reinfoced front edge with 1.5" aluminum l channel. $35


    That was basically the repair that I had planned to do on my own if they refused to do anything with it, but since I had a few small items that needed warranty work, I figured it was worth a try. Normally I avoid the dealer at just about any cost and just take care of things myself.

    Of course there is no such thing as a "free lunch". When I went to pick it up yesterday, the battery was totally dead. I had disconnected the battery when I dropped it off but the tech must have reconnected it when they started working on it 6 weeks ago and used it for interior lighting. I jumped it to the truck and got the generator started but even after 20 minutes of charging the battery was too far gone to keep the generator running. I finally gave up and got one of the clowns in the shop to bring out a jump box so I could pick the jacks up and leave. With a little bit of effort, it seemed to take a charge so I guess we'll have to see how it does in the future. Oh well, I've been wanting to go to dual batteries anyway and a new battery is still cheaper than all the repairs that they made if I have to buy one.
  • Ts1 wrote:
    I repaired my own in our fuzion. With help of a friend, removed bed, removed million staples, layed a sheet of 3/8 sanded plywood and screwed together. Restapled materiel and reinfoced front edge with 1.5" aluminum l channel. $35


    Did basically the same to my Raptor rear bed...:)
  • I repaired my own in our fuzion. With help of a friend, removed bed, removed million staples, layed a sheet of 3/8 sanded plywood and screwed together. Restapled materiel and reinfoced front edge with 1.5" aluminum l channel. $35
  • They are replacing the bed with a new unit. The frame is only a 2x4 laying on its side so my suspicion is that there was a big knot in the middle of it creating a weak spot. The frame nearest the ramp door seemed fine so there has to be some sort of flaw in the wood that made the front frame weak.
  • Can you share what they did. The perimeter frame is pretty strong but the base seems to be made of leftover paneling from the 70s. Sags with the weight of the mattress.
  • Our rear pull down queen bed will support 600 lbs, its very strong.