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RE: Coleman Leaf Spring Upgrade

Started by SCCS, Aug 03, 2003, 12:03 AM

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Ab Diver

 I have a  98 Coleman Bayside. I love the trailer, but it lacks enough cargo capacity to really make it useful. A lot of our *stuff* must be carried in the tow vehicle. I ve found a way to upgrade the Cargo Capacity of my older trailer, and certain other Coleman pop-ups. Many of us know how heavy the larger 12  box pop-ups are, straight from the factory. Counting the weight of any *options* you add (such as a Furnace, Awning, Add-A-Room, roof-mounted bike racks, etc.), toss in a few items like propane, batteries, paper plates and sleeping bags, and you soon run out of room on the Gross Vehicle Weight Rating (GVWR) for luxuries like food, water, and clothing.
 
 I ve noticed how the GVWR on these pop-ups has creeped up over the last few years. My pop-up has a GVWR of 3250 lbs., and an Gross Axle Weight rating (GAWR) of 2950 lbs.  A 2002 Bayside has a GVWR of 3450 lbs., while a 2003 Bayside has a GVWR of 3600 lbs.  All these trailers use the same Dexter 3500 lbs. axle, and come with the same Duro tires (ST185/80D13 were the originals on my trailer) rated at 1660 lbs @ 65 psi. The Tongue Weight Rating (TWR) has gone up as well, from 300 lbs. on my  98 to 400 lbs. on the current models, while nothing has changed on the trailer s A-Frame itself (confirmed by Coleman on the phone, while researching adding the dual 6V batteries to my trailer).
 
 So where did the extra Weight Rating come from? While attending a large rally of fellow pop-uppers, I crawled under and around a few different trailers to see if there were any differences in the tires, axles, suspension, and frame. There were: the leaf springs were different.  My older Coleman uses a 3-leaf slipper spring rated at 1500 lbs. each, hence my 2950 lbs. GAWR. The new Colemans use a 4-leaf slipper spring. The only difference is the addition of the fourth leaf, 8"  long, on the bottom of the spring. The other 3 leafs are the same length, width, and thickness as mine.
 
 After some information passed on by *mike4947* and *SCCS* (AKA: Scott), and some phone tag with Dexter and Coleman, I ve found that the 4-leaf slipper spring (Fleetwood part # 4735H22061) used on the newer Coleman trailers is a direct bolt-on replacement for my 3-leaf slipper spring. These springs are rated at 1750 lbs. each, or 3500 lbs for the pair.  I ve just finished switching the springs, and the tires are in exactly the same place, neither in front nor behind their original position. This was crucial to me, since I run larger 14"  tires on my trailer, and wheelwell clearance was critical. For most people, the fourth spring will not alter ride height, but I use the Dexter Over/Under Axle Kit (lift kit), so I gained the thickness of one spring in ground clearance.
 
 Cupla things....
 
 1) I am the second owner of my trailer, and as such, have no warranty to void. Coleman was very specific in that such a modification to a trailer by a *first* owner could void the trailer s warranty (Read: covering their backsides. Can t blame them for that, really.)
 
 2) My local Highway Patrol office said that using these springs wouldn t get me into trouble for exceeding the GAWR or GVWR,  since the part that rating was based on had been upgraded. Just keep the leaf spring part number handy as proof.
 
 3) If you do this mod on your older Coleman trailer, this DOES NOT mean you can load 3500 lbs on your axle.  Your Duro tires will now be the weak link. Do not exceed their weight rating (1660 x 2 = 3320 lbs).
 
 My ST205/75D-14 Tow-Master tires are rated at 1760 lbs @ 50 psi, so I don t have to worry quite so much, but I still don t plan on pushing the axle to it s limit. All I wanted was a couple hundred pounds of extra cargo capacity, and this mod will easily allow my trailer to carry that load safely.
 
 This was a pretty simple mod to do. It s a straight un-bolt, bolt-on job. First, I hitched up the trailer to my truck as a safety precaution, so the trailer couldn t move forward or backward off the jack stands. This also insures that the front half of the trailer is supported, even if a small earthquake knocked it off the jackstands (California thing [;)] ). Jacked up the trailer, blocking it up *securely* with the jack stands just behind the axle. Removed the tires. Had a couple extra smaller jack stands handy to support the axle after it was unbolted from the springs, but some blocks of wood could suffice. Used the floor jack to raise the axle into position after the new springs were in place. If you don t have these things laying around, a third hand (read: a helper who works for the price of a cupla beers) comes in handy at this point. Be careful not to let the axle drop to the ground and rip the brake wires from the frame-- that s why I used the extra jack stands. I bought a new set of U-bolts and shackle bolts, just to be safe. Then it s just a matter of putting everything back together the way you found it.
 
 Total time:  bout an hour, from initial hitch up to final lug-nut torqueing, working slow and having fun. Cost: $92.24 for the springs, and 21 bucks + change for the new bolts. Note: doing this job on concrete and having a cheapo $20 mechanics creeper from Wall-Mart really made the job easy. If your tow rig sits low, backing it up onto some wood blocks to raise the trailer s tongue will help give you some additional room under the trailer in which to work.
 
 Granted, this mod will not be for everyone. But if you are the owner of a " new-to-you"  older Coleman trailer, and would like to upgrade your carrying capacity a bit, this will help.

SCCS

 Ab DiverHey Dave,
 
  Glad to see that you are feeling better. I am interested in doing this to my trailer also. Are the springs the same width (1 3/4" ) as the 3 leaf spring? Who did you order them from?

Ab Diver

 Ab DiverScott, the springs are the same width as the old springs. They slip right into the shackle just as the old springs did. I ordered them from my nearest Coleman dealer (Bria Recreation in Santa Rosa), but the springs came direct from Fleetwood in Somerset, PA.... or at least that was the return address on the UPS box. [;)]
 
 The only other difference I could see, besides the fourth leaf, is a rubber-padded metal " band"  around one end of the top two (longest) springs. Dunno if that serves as part of the increased load capacity of these springs, or simply helps keep them in line with each other. My old 3-leaf springs had no such band around the top two leafs.
 
 I bought the new U-bolts as an axle kit from our local RV repair shop here in town. Hand tightened the nuts on both sides of the axle, then torqued them down on one side to 30 lbs., working around all four bolts a quarter turn at a time so the bolts would tighten evenly around the axle. Moved over and did the other side of the axle. Then reset the torque wrench to 40 lbs., and torqued both sides again. These new 1/2"  thick U-bolts were much thicker than the stock U-bolts (even thicker than the ones on the Dexter Lift Kit, which called for 60 lbs.), so I didn t want to over-torque them and risk dammaging the axle. From the looks of things, they ain t going nowhere. [:)]

champ521

 Ab DiverI have been buying stuff and loading it into my PU and TV since I found this website. I think that if I have a problem with overloading, I will blame it on someone else (DW) because if I have room for it, it fits! Now if I was driving a one ton truck I would not be worrying about what I put in the PU.[: (]Yeah, that s green with envy.

tlhdoc

 Ab DiverDave did you take any pictures of the switch.

mike4947

 Ab DiverDave, GREAT MOD. Works especially well with the 14 inch tires. You get extra capacity and still have a margin of safety. IMHO you ve got a better combination than even the newer trailers from Coleman with their new 3770 GVWR. The 13 inch tires they use now seem to be harder to find and they are at their limits which doesn t make me comfortable. Over the years I ve found tires at their limits don t last as long as one with a little cushion.
 Again great job, got my vote for " Mod Of The Year"

Ab Diver

 Ab Diver
QuoteNow if I was driving a one ton truck I would not be worrying about what I put in the PU.

 Actually, Dave--- *YOU* are partially responsible for my need to move stuff from truck to trailer. Seems my girls fell so much in love with The Min Pin (and Sadie, Sophie, Kirby, and all the other Pop-Up Pups) that I will need to find space in the back of the truck for a traveling crate. They keep showing me pictures of Pugs, Pomeranians, Australian Shepards, and something called a GoldenDoodle (looks like some kind of animal vaguely resembling a dog with a REALLY bad hair day). Now see what you gotten me into? [;)]
 
 
QuoteDave did you take any pictures of the switch?

 Sorry, Tracy... the DW just got back from a trip to see family, and when I went to grab the camera (I did, I really did), she d used ALL the film, even the spare roll we usually keep in the house. I wanted to get a shot of the before, after, and both springs laying side by side for comparison. But the end result is that it looks exactly like the axle/spring suspension found on a 2003 trailer-- nuthin  exotic about that. Not to worry though, I ll snap a shot or two with the next roll, scan  em, and send them to you if you d like.
 
 Wow, Mike... coming from you, that s pretty strong praise. Dunno if it s worthy of such a title, but I sure appreciate the " nomination" . Thanks!
 
 

mike4947

 Ab DiverWell don t get a swelled head.[:D] The nomination is for the Lift kit, 14 inch tires and the springs. It s the combo that rates it as excellent.

Ab Diver

 mike4947
 
QuoteWell don t get a swelled head.

 Who, me? (hands clasped behind back, scuffing toe of boot in dust) No way. And after last month s bout with a bug that cost me 15 lbs (and two hospital ER visits) for a headache that double Percosette couldn t touch, I don t  even wanna *think* about that visual,  kay? [;)]
 
 
QuoteThe nomination is for the Lift kit, 14 inch tires and the springs. It s the combo that rates it as excellent.
 

 Ok, that s better. Agreed. I didn t plan it that way, but that s how it wound up. Sometimes, we get lucky.

tlhdoc

 Ab Diver
QuoteORIGINAL:  Ab Diver
 
 
QuoteDave did you take any pictures of the switch?

 Sorry, Tracy... the DW just got back from a trip to see family, and when I went to grab the camera (I did, I really did), she d used ALL the film, even the spare roll we usually keep in the house. I wanted to get a shot of the before, after, and both springs laying side by side for comparison. But the end result is that it looks exactly like the axle/spring suspension found on a 2003 trailer-- nuthin  exotic about that. Not to worry though, I ll snap a shot or two with the next roll, scan  em, and send them to you if you d like.
 
 

 Thanks Dave I would like that.