Anyone broken a Hensley?

If you mean that you just broke the lower hitch head, the black part that houses the lower two bearings and the spring bar ends then yeah, I broke one too. I bought my HA used for cheap and made a small weld repair when I had it apart for refurbishment, 2 years and 15,000 miles later I noticed that the area I had welded was recracked (tube that holds the spring bar bushings where it mates to the bottom plate) and there was some more cracking on the tubes themselves. I bought a new lower head unit for about $750 or so from Hensley, if you are the original owner or have bought it used and purchesed a lifetime warranty from them you should be covered. Fairly easy to remove and replace too, just disassembly of 2 bearing sets then 2 new seals and reassemble the bearings. My new unit also came with new overcenter latch assemblies.