16-006

TECHNICAL SERVICE BULLETIN
TSB#: 16-006
Date of Publication:
Job Code: 9801285
TSB 13 Inspect .3 hr
TSB 14 Inspect and Rpr
1.5 hr
February 2016
NOTE: This Technical Service Bulletin will be valid within (1) year from the original date of publication.
PARTS ORDER REQUIRED
ACTION REQUIRED
Inspect the brake wiring on axles.
If the wiring is on the Door Side of the trailer, axles must be reversed.
MODELS / UNITS
2016 Octane Travel Trailer
T30F
G1VF
0052-0057, 0059-0069, 0072-0073, 0075, 0078, 0080-0082
Note: Parts kit must be ordered on TSB 16-006 order form on file.
PARTS KIT
16-006JT
1
6
6
5
5
1
Brake cable 12ga 2 conductor 6-1/2 feet long
Crimp sleeves, copper
Insulators, rubber covers for crimp sleeves
P-clamps
Screw hex wshr TEK #14 x 1"
Hardware kit for tandem axle
TOOLS/SHOP SUPPLIES
4 Jack stands (minimum 6,000 lbs each)
Wire Crimpers
Wire Cutters
Impact driver
Impact sockets - 3/4", 11/16"
Wrench 13/16" open end / box end wrench
Floor Jack
Safety glasses
Torque Wrench (Ft / lbs)
3/8 Socket adapter
Small sledge hammer
6-1/2 ft cable
3/8 Socket adapter
INSPECT BRAKE WIRES
Door Side
of trailer
Brake cable
from front
of trailer
Brake
wiring
This short
cable will be
re-used on
Off Door
Side
FIG 1
1
FIG 2
Door Side
of trailer
Fig 1: Inspect for location of the brake wiring. Removal of wheel is NOT required to inspect wiring,
Fig 2: Notes Brake wiring on the Door Side.
NOTE: The short cable going between the wheels, will need to be moved over to the Off Door Side in step 4.
16-006 Axles Reversed
February 2016
1 of 4
INSTRUCTIONS
FIG 3
2
FIG 4
Fig 3: Loosen all lug nuts with the 3/4" socket and the impact driver.
Place four floor jacks under the trailer frame to lift the entire trailer and wheels off the ground. Remove all 4 wheels.
NOTE: FLOOR JACKS MUST BE A MINIMUM OF 6,000 LBS EACH
Fig 4: Place a floor jack up under each axle to support it as the mounting bolts are removed.
Short cable
from front
axle to rear
axle
Cut wire
Brake cable
from front
of trailer
Brake
wire
Brake
wires
FIG 5
3
FIG 6
Fig 5: The wires are crimped with copper connectors. The wires will need to be cut off right behind these crimp connectors.
This photo shows cutting the brake wire just behind the crimp connector.
Fig 6: Once the wires have all been cut and separated, you should have:
The short cable between the axles (white & blue), the brake cable from the front of trailer (white & blue) and the 2 brake wires.
At this time, remove the short cable from the frame that goes between the two axles.
This short cable will be re-used again on the other side of the trailer.
Remove spring
Equalizer bolt
Remove
spring bracket
bolt
FIG 7
4
FIG 8
Fig 7: Remove the front axle from the frame bracket and the spring equalizer.
Use the impact driver with the 11/16" socket, and the 13/16" wrench to remove the bolts holding the springs to the bracket.
BE SURE THE FLOOR JACK IS UNDER THE AXLE.
Fig 8: Remove the bolt holding the springs to the equalizer. Requires the same tools as Fig 7. DISCARD ALL OLD HARDWARE!
Go to the other side of the coach and remove the same bolts to free the axle.
Lower the front axle to the floor.
Repeat the procedure for the rear axle using the same tools.
WARNING: MAKE SURE THE FLOOR JACK IS SUPPORTING THE REAR AXLE BEFORE REMOVING SUPPORT BOLTS.
16-006 Axles Reversed
February 2016
2 of 4
Wires should be
stripped about
1/2" as shown
3"
FIG 10
FIG 9
5
The brake cable runs down the frame rail on the Door Side from the front of the trailer (See Fig 6)
The 6-1/2 ft cable that comes in the kit needs to be attached to this brake cable, and then run across the trailer to the Off Door Side.
Fig 9: Strip back approximately 3 inches of the outer sleeve on each end of the 6-1/2 ft cable.
Strip back 1/2" of the insulator at the end of each wire (white and blue).
Blue to Blue
White to White
FIG 11
6
7
Fig 11: On the Door Side of the Trailer: Splice white wire on the brake cable to the white wire on the 6-1/2 ft cable.
Splice the blue wire on the brake cable to the blue wire on the 6-1/2 ft cable.
Use the copper crimp connectors on these two splices.
Fig 12: Install a rubber insulator cap on each pair of wires (white and blue).
Hang cable up out of the way using a P-clamp and TEK screw mounted in the frame not the underbelly material.
Run the 6-1/2 ft cable across the trailer to the Off Door Side.
CAUTION: WATER TANK(S) ARE IN THIS AREA DIRECTLY ABOVE THE UNDERBELLY.
Attach P-clamps to the steel angle on the underbelly to route the cable using the TEK screws.
DO NOT RUN SCREWS UPWARD TOWARDS THE UNDERBELLY.
P-CLAMPS SHOULD ONLY BE INSTALLED IN STEEL UNDER THE TRAILER - NO SCREWS TOWARD THE UNDERBELLY!
Take care that you do not pierce the water tank(s) with a screw.
Off Door
Side
FIG 13
8
FIG 12
TORQUE TO 45 FT/LBS
Off Door
Side
TORQUE TO 45
FT/LBS
FIG 14
Fig 13: Rotate the rear axle 180 degrees so the wiring is on the Off Door Side of the trailer. Lift the axle with the floor jack.
Mount the axle to the spring brackets and the equalizers on each side of the trailer using new hardware.
Make sure the bolts seat all the way against the brackets. If they don't; you may have to hit them with a small sledge hammer.
Fig 14: Rotate the front axle 180 degrees so the wiring is on the Off Door Side of the trailer. Lift the axle with the floor jack.
Mount the axle to the spring brackets and the equalizers on each side of the trailer using new hardware. (Make sure bolts are seated)
16-006 Axles Reversed
February 2016
3 of 4
RE-MOUNT THE SPRINGS USING ONLY NEW HARDWARE FROM THE KIT.
Tighten all the mounting hardware using the impact driver and open end wrench.
TORQUE THESE SPRING MOUNTING BOLTS TO 45 FT/LBS
6-1/2'
cable from
Door Side
Off Door
Side
Short cable
taken from
the Door Side
Brake
wires
Off Door
Side
FIG 16
FIG 15
9
2 Blue wires
and 1 brake wire
Fig 15: You should have two pieces of cable and two brake wires as shown here.
Strip back 1/2" of the insulation on each wire (including brake wires).
Fig 16: Crimp two blue wires (one from the 6-1/2 ft cable and one from the short cable) and one of the brake wires.
Then crimp two white wires (one from the 6-1/2 ft cable and one from the short cable) and the other brake wire.
FIG 17
Off Door
Side
FIG 18
TORQUE LUGS TO 110
FT/LBS
10 Fig 17: Add a rubber insulator cap over the crimp connector on both sets of wires.
Secure the 6-1/2 ft cable up to the frame so it doesn't get tangled in the springs or wheels.
Secure the short cable up to the frame rail to keep the wires from getting tangled in the wheels or equalizer.
Fig 18: Re-install the wheels and lug nuts.
Remove the floor jacks on the four corners of the trailer.
Torque lug nuts to 110 ft/lbs. using the 3/4" socket and torque wrench.
16-006 Axles Reversed
February 2016
4 of 4
February 2016
Technical Service Bulletin Notification TSB #16-006
«NAME»
«Name_or_address»
«City»
«St» «STZIP»
Dear Valued Jayco RV Dealer:
Jayco has determined that certain Model Year 2016 Octane T30F Travel Trailers require
inspection for possible axle reversal to maximize tire wear and the life span of the brakes.
Our records indicate that the following units are currently stock at your dealership and are
included in this Bulletin and require the repair prior to being retail sold:
Serial Number
The coverage period for this Technical Service Bulletin is for one (1) year from the release
of this notification. (February 2016- February 2017). If you have sold this affected vehicle,
please contact the current owner regarding this Service Bulletin and process the Warranty
Registration for this customer. All pertinent information regarding this Bulletin is on file under
the Service and Parts Tab of Jayco Partners. If you have questions regarding this Service
Bulletin, please contact Jayco Customer Service at 800-283-8267.
We apologize for any inconvenience this may cause. However, we are confident that this
improvement will offer continued satisfaction to our customers with their Jayco Octane Travel
Trailer.
Sincerely,
Jayco Towable Division
February 2016
Technical Service Bulletin Notification TSB #16-006
Unit Serial Number
Dear Valued Jayco Owner:
Jayco has determined that certain Model Year 2016 Octane T30F Travel Trailers require
inspection for possible axle reversal to maximize tire wear and the life span of the brakes.
Our records indicate that your Recreational Vehicle is affected by this service bulletin. Please
contact your nearest Jayco dealer to schedule an appointment and present this letter as
authorization to have the procedure completed at no cost to you.
The coverage period for this Technical Service Bulletin is for one (1) year from the release
of this notification. (February 2016 – February 2017) If you have sold or traded your vehicle,
or for any reason cannot have this service performed, please contact the Jayco Customer Service
Department at 800-283-8267.
We apologize for any inconvenience this may cause. However, we are confident that this
improvement will offer continued satisfaction with your Jayco travel trailer.
Sincerely,
Jayco
TechFlyer
SPRING 2016
Ordering Chairs and Sofas Online
Due to variances in import and domestic soft goods from Lippert Interiors, we ask that when ordering any sofa or chair, please submit your
order as an Unknown Part Number request and upload photos as noted below. We will complete the research for the correct chair or sofa.
Stabilizer Jack - Non Warrantable Damage
The stabilizer jack is designed as a four corner stabilizer. The jack is not to be used to lift the trailer. Damage to the jack can occur
from lifting the trailer using the jack. Signs of a damaged jack from lifting the trailer are damage to the front trunnion area and drive
rod and /or a bent leg. A stabilizer jack that is bent is not covered under warranty and the claim is subject to denial.
TechFlyer
Any input or comments for this newsletter and technical website may be sent to:
Diana Niswonger, Editor • [email protected]
Subject: Tech Flyer
© 2016 Jayco, Inc.
Published by Jayco Service for all Jayco RV Dealers.