I sent my Hensley back to the factory for a total rebuild, twice. Originally, the weld around the spring bar tube in the lower assembly was cracked. Because I was paying about $200 in shipping charges, I also returned a few bent, broken, worn, and cracked parts for warranty replacement; the hitch is 17 years old. They replaced all the parts, plus rebuilt the main assembly with new bearings and everything, except------they did not repair the crack. They paid for the return of the hitch to repair the crack, and I also mentioned that the ball was loose. I could move the ball front and back as well as rotate it clockwise and counter-clockwise about 1/8 - 3/16th inch. And I could easily push the pin through the ball, back and forth. I asked that the ball be checked. When I boxed the hitch, I taped a piece of printer paper to the hitch with an arrow drawn to the crack and to the ball with a note for each. This time they replaced the lower assembly, but did nothing to the ball. So, my question after all this trivia, is: "is the ball supposed to move on the stud and is the pin supposed to be loose enough to push back and forth with your fingers?". I've never had a ball like this so I'm ignorant on it's operation. I need to contact Hensley tomorrow morning, sot any prompt reply would be appreciated. Thanks for any input.

So, 66 looks and no one has information on this type of balll? Maybe my description wasn't good. The ball is partially hollow and slips down onto a large stud; it's held in place by a large steel pin that slips through the ball and stud. Should there be any loose play between the ball and stud? I could really use some experienced information about this.

My ball is welded, I believe. So I'm no help. I would physically call Hensley and ask about the ball. I don't think it should move at all. The ball moving would allow the strut bars to loosen/tighten as the ball moved on the upper unit...

Thanks, Richard, I'm calling this morning, but wanted a little information first.

Let us know the outcome . . . . :h

My ball is also welded on so there is no movement. It sounds like yours has a Convert-a-ball system on it. Didn't know Hensleys came with that. I used to have one of those and it worked fine. The pin had O rings on it which kept it in the hole in the ball. I also don't remember the ball being loose at any time. It was a neat system that allowed you to change balls easily when towing different trailers with different sized couplers. Perhaps yours has the pin or the hole where the pin fits worn excessively. It is also possible that the part the ball fits onto (cone part) is not tightened completely on the mount of the hitch head. I would definitely ask Hensley about this.Barney

Hensley hitch question | Good Sam Community

clev
Explorer
Aug 18, 2013
Paul, Hensley used Adapt-a-Ball for the first few years, through about the early '90's. The Adapt....... had a hexagonal (6 sides) stud welded to the top plate. They used that design for the consumer. You could use fhe 2 5/16 ball or pull the pin and use another size ball. About 1987, Adapt......went out of business, but some companies still had their hitch balls; Hensley was one of them, and I received one of their designs in 1997. After that, Hensley welded the ball to the top plate. Hensley is a great company and makes a remarkable hitch. Even with the problems that I'm having, I'd never use any hitch but a Hensley.
peirek
Explorer
Aug 17, 2013
clev wrote:
Hi Paul; follow this link, www.convert-a-ball.com

And yes, my Hensley has a hexagonal shaped stud, with a hole through it near the top, welded to the top plate. A ball with a hexagonal shaped opening and a pin hole drilled through it from side to side, slips over the stud, and a pin is inserted into the ball, through the stud, and flush with the other side. This ball is what is loose on my hitch. I knocked the pin out, took a picture, and sent it to Hensley. Yesterday, I was assured that the pin was in good shape and the ball, even when new, had a lot of 'play' in it. Today, with the pin out, I noticed the hole was obstructed, and driving a punch through it, another piece of pin came out; the pin was obviously broken. I've taken new pictures and sent them along with a lengthy e-mail to Hensley. Hopefully, I'll get this resolved on Monday. Also, when my hitch was installed, I had a zerk fitting installed in the top of the coupler and do not need to drop the hitch in order to lube it.

You have my curiosity up now on what exactly is on mine. Really like the idea of the zerk in the coupler. I will put that on my list for upgrade.
clev
Explorer
Aug 17, 2013
Hi Paul; follow this link, www.convert-a-ball.com

And yes, my Hensley has a hexagonal shaped stud, with a hole through it near the top, welded to the top plate. A ball with a hexagonal shaped opening and a pin hole drilled through it from side to side, slips over the stud, and a pin is inserted into the ball, through the stud, and flush with the other side. This ball is what is loose on my hitch. I knocked the pin out, took a picture, and sent it to Hensley. Yesterday, I was assured that the pin was in good shape and the ball, even when new, had a lot of 'play' in it. Today, with the pin out, I noticed the hole was obstructed, and driving a punch through it, another piece of pin came out; the pin was obviously broken. I've taken new pictures and sent them along with a lengthy e-mail to Hensley. Hopefully, I'll get this resolved on Monday. Also, when my hitch was installed, I had a zerk fitting installed in the top of the coupler and do not need to drop the hitch in order to lube it.
peirek
Explorer
Aug 17, 2013
clev wrote:
Hi Paul. Was my description of the movement on the stud not clear?

Maybe for some but not me.... ;) I guess I never really paid attention to the ball on the hitch head. After re-reading, are you saying there is a stud welded to the hitch head and the ball screws down on it? And this is what is loose? I am having a hard time because I have never seen this arrangement. My (admittedly little) experience with balls is they have a stud and nut. Sorry for my confusion and lack of experience.
clev
Explorer
Aug 16, 2013
Hi Paul. Was my description of the movement on the stud not clear?
peirek
Explorer
Aug 16, 2013
clev wrote:
Thanks Barney. As stated, my hitch was purchased about 17 years ago and came with that particular ball. I actually never saw it because it was dealer installed. The stud is not bolted to the hitch head, it's welded and appears to be secure. I called Hensley this morning, and they're giving me a bit of a hard time over it. Even though I've had to send it back twice and lose 5 weeks of my wife's summer vacation, I've appreciated the work they've done. But I'm not impressed with their inspection process.

Are you saying the ball is moving on the Hensley head? Or it is moving in the coupler? I think you are stating in the coupler. If that is the case, you might check your coupler adjustment. There is usually a nut to adjust the coupler "claw" as it engages the ball. After 17 years it may have worked loose. That might also explain the cracks if it was floating and causing undo stresses.

BTW I just finished the yearly decouple process to clean and grease the ball/coupler. It is a recommended maintenance procedure. Even though the head does not rotate on the ball, it does go up and down. It is also a good time to check the coupler fit.
clev
Explorer
Aug 16, 2013
Thanks Barney. As stated, my hitch was purchased about 17 years ago and came with that particular ball. I actually never saw it because it was dealer installed. The stud is not bolted to the hitch head, it's welded and appears to be secure. I called Hensley this morning, and they're giving me a bit of a hard time over it. Even though I've had to send it back twice and lost 5 weeks of my wife's summer vacation, I've appreciated the work they've done. But I'm not impressed with their inspection process.
BarneyS
Explorer III
Aug 16, 2013
My ball is also welded on so there is no movement. It sounds like yours has a Convert-a-ball system on it. Didn't know Hensleys came with that.

I used to have one of those and it worked fine. The pin had O rings on it which kept it in the hole in the ball. I also don't remember the ball being loose at any time. It was a neat system that allowed you to change balls easily when towing different trailers with different sized couplers. Perhaps yours has the pin or the hole where the pin fits worn excessively. It is also possible that the part the ball fits onto (cone part) is not tightened completely on the mount of the hitch head. I would definitely ask Hensley about this.
Barney
TenOC
Nomad
Aug 16, 2013
Let us know the outcome . . . . :h
clev
Explorer
Aug 16, 2013
Thanks, Richard, I'm calling this morning, but wanted a little information first.

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