On edit - of course AFTER I wrote and posted this, I actually saw the sticky for the very same procedure. I included "a little long" in the subject, so NOW if anyone doesn't want to read all the words, you won't have to. I know reading is a pain, sometimes.
A few days ago, I finally had the time to install a set of shocks and the Equa-Flex from Trailair Service Center (trailair.com) to try and get a better towing experience from the TT in my sig.
I was skeptical at first, for a couple of reasons.
First, I didn't want to attempt this project by myself, mostly because two sets of eyes are usually better than one.
Second, I wasn't so sure upgrading the suspension was going to fix the way the TT would act while on the road.
A little background: We've put several thousand miles on this TT, and from the beginning it seemed to have a real problem with sway. Forget passing trucks, forget wind, and all the other usual causes. I was convinced the engineer that designed this frame/suspension must've been asleep the day they talked about weight & balance in Engineering 101.
It seemed the TT would have excessive reaction to any and all steering inputs. Even the slight left/right inputs we all do to keep our vehicle centered in the lane.
Wag, wag, wag.... sway, sway, sway..... what a gigantic pain.
Anyway, I thought I was going to use a "retrofit kit" that came with a new spring retention plate that had a lower shock mount built in. It also had instructions that indicated that you must drill a 1/2" hole in the frame (this one is an I-beam type), insert a long bolt, and using some supplied spacers, this would be the top shock mount.
You know how if something is meant to be, it'll kinda just happen in spite of your best efforts?
Well, that's how this "shock kit" was going, only in reverse.
Turns out neither I nor the manager of the parts dept. at my RV dealer were smart enough to actually check the retrofit kits I bought to ensure they would fit the 3" axles on my TT. His excuse was that he was under the weather. My excuse? Off in Gumbyland, I guess.
So I ask Jeff, the manager, if there was something he would recommend to cure the towing problems. I trust what this guy says, he's proven his worth several times in the past. He suggests these kits, and a quad-pak of Monroe gas shocks that they "got a good deal on".
Ok, I'll bite. How much? says I.
"Well", he says, "the retrofit kits are 50% off, and since we got a great deal on these shocks, I'll say.... $65 bucks" says he.
What? $65 bucks.... that's it???? says I.
"Yep, that's it." says he.
SOLD, says I.
Got all this stuff home only to discover the retrofit kit wouldn't fit. Great. I'm only slightly surprised at this.
After several phone calls to Jeff, and several more on his part to the manufacturer of the kit, and after several days of waiting to hear from them, turns out they don't have any for 3" axles, and don't know when any more will be available. Great again. Not surprised one bit at this.
A few more days of talking to Jeff, and a little more research on my part, I come up with a brilliant idea.
I discovered that the Designer Series of Jayco's come with shocks installed from the factory.
So, I call Jeff and ask "Why can't we get the parts from the factory and install THAT?"
The next day he checked around and turns out they have the parts in their shop area already.
So, I purchased the 4 spring retention plates that would accommodate the type of shocks that have a stud on each end, 4 upper shock mounts, and 4 Dexter shocks. The upper shock mounts would have to be welded on.
No problem there, that's exactly why I picked up a MIG welder a few years ago.
Jeff also ordered the Equa-Flex from Trailair. He also ordered the wet bolt kit, that also contained new bushings and grease fittings for the bolts. It arrived within 3 days.
Well, I got my brudder-in-law to assist.
We got both tires off one side first, and supported the trailer by the frame with 2x4 cribbing.
The first side wound up taking 4.5 hours from start to finish to install the new shocks, shock mounts, Equa-Flex, and all new bushings.
BTW, did you know that the factory uses PLASTIC bushings on those springs? Now that was a surprise.
We took the end of each spring that bolts directly to the frame off first.
Little did we know at the time that this was a mistake.
Pulled that plastic garbage out, lubed up a new bronze bushing and drove it into the spring eye. Dry fit the wet bolt into each new bushing, and being satisfied that all was good, we proceeded to attempt to reinstall the spring into the hanger.
We must've looked like a couple of monkeys wrestlin' a football trying to get those springs to cooperate.
With a little extra persuasion from pry bars and a cum-along, we were finally able to get both ends back into their hangers.
Now for the middle... the existing knuckle and shackles.
While the axles were being supported from below, we carefully removed the shackles, factory knuckle, dry as heck bolts, and those crummy plastic bushings.
We lubed and installed the new bushings, new shackles (1.5 inches longer than factory) and wet bolts.
Installed the Equa-Flex to the hanger on the frame, THEN tried to get both sets of shackles to mate up with the Equa-Flex.
More monkeys wrestlin' a football at this point.
Finally got all of it put back together and greased.
Enough for one day.
Next day, tackled the other side. This side only took 1.5 hours to complete. No kidding.
Changed the procedure quite a bit.
Took EVERYTHING loose from the frame, knuckle, shackles and supported it from below with 2x4 cribbing.
Removed the knuckle, all crappy plastic bushings, and shackles.
Lubed and installed all bushings.
Installed the Equa-Flex and shackles.
Reinstalled the outside ends of the springs first, then used a 2 ton floor jack to push the Equa-Flex up into it's hanger.
It's amazing how something so easy can be so complicated when being attemped by a couple of monkeys who are more interested in wrestlin' footballs.
Took the TT out today for a test tow.
It's amazing how the proper suspension can improve the handling of the TT.
I hope the description of this project is clear enough to help someone else that may want to take it on.
Didn't get any pictures of the process, but if anyone wants to see what it looks like, I'll snap a couple and post them.
BTW, because of the longer shackles, the TT sits about 1.5 inches lower than it used to, which is fine by me. I think that also helped improve the towing of this TT.
