Coleman pop-up roof stuck up

[jdavino]

Hi All,

I have a 2000 Fairview Fleetwood Folding trailer.  Last weekend I went to pop it up to do some general maintenance.  I cranked the roof up until it wouldn't go any further.  It didn't seem like it was all the way up, but I wasn't sure.  I went inside the camper and when I went to put the door in place it became apparent the top wasn't all the way up.  I then went back outside and was able to force about two more turns out of the crank.  It still wasn't all the way up, so then I decided I better not force it any further.  I then tried to crank the top down, but the handle just spun and the top didn't move.  When I tried to go back the other way again (up direction) I got the same result.  The handle can turn round and round but the top doesn't go anywhere.

I got underneath the camper and took the cover plate off to try and figure out what was wrong.  There was a nest tangled up in the screw near the block where all the cables attach.  I cleaned the nest out, but the system still doesn't work.  When I turn the crank in either direction the screw turns a little bit then stops and the handle just goes around.  It seems like there is a problem with the coupling between the crank and the screw.

I'm not overly mechanical, but I would like to somehow get the top down so I can drive the camper to the local RV dealer for repair.  If anyone has some insight into this problem and can explain to me how to get the roof down, it would be greatly appreciated.

Thanks,
John

[wavery]

Hi All,

I have a 2000 Fairview Fleetwood Folding trailer.  Last weekend I went to pop it up to do some general maintenance.  I cranked the roof up until it wouldn't go any further.  It didn't seem like it was all the way up, but I wasn't sure.  I went inside the camper and when I went to put the door in place it became apparent the top wasn't all the way up.  I then went back outside and was able to force about two more turns out of the crank.  It still wasn't all the way up, so then I decided I better not force it any further.  I then tried to crank the top down, but the handle just spun and the top didn't move.  When I tried to go back the other way again (up direction) I got the same result.  The handle can turn round and round but the top doesn't go anywhere.

I got underneath the camper and took the cover plate off to try and figure out what was wrong.  There was a nest tangled up in the screw near the block where all the cables attach.  I cleaned the nest out, but the system still doesn't work.  When I turn the crank in either direction the screw turns a little bit then stops and the handle just goes around.  It seems like there is a problem with the coupling between the crank and the screw.

I'm not overly mechanical, but I would like to somehow get the top down so I can drive the camper to the local RV dealer for repair.  If anyone has some insight into this problem and can explain to me how to get the roof down, it would be greatly appreciated.

Thanks,
John

It sounds like the pawl might be dirty and stuck and the cable may not be wrapping correctly.

Before you attempt any repair, it may be a good idea to get 4 - 2x4s, cut them to length and put one in each corner of the roof to support it. Also, be sure that the camper is level. Never crank your top up if the camper is not relatively level but in this case, it should be level.

I would get in there with some WD40 and a paint brush and clean the entire mechanism all out real good. Make sure that the pawl is free. Also clean all of the other pulleys and inspect all of the cable that you can see. After the WD40 dries, be sure to lubricate all of the moving parts with silicone spray.

With the roof supported, turn the crank counter-clockwise a few turns, then go under there an make sure that the cable is neatly wrapping on the pulley. Then turn the crank clockwise until you reach reach the top (being sure that the cable is still wrapping neatly). Once you reach the top, the pawl should reset itself and allow you to crank the roof down.

Good luck.

[Old Goat]

It sounds like the pawl might be dirty and stuck and the cable may not be wrapping correctly.

Before you attempt any repair, it may be a good idea to get 4 - 2x4s, cut them to length and put one in each corner of the roof to support it. Also, be sure that the camper is level. Never crank your top up if the camper is not relatively level but in this case, it should be level.

I would get in there with some WD40 and a paint brush and clean the entire mechanism all out real good. Make sure that the pawl is free. Also clean all of the other pulleys and inspect all of the cable that you can see. After the WD40 dries, be sure to lubricate all of the moving parts with silicone spray.

With the roof supported, turn the crank counter-clockwise a few turns, then go under there an make sure that the cable is neatly wrapping on the pulley. Then turn the crank clockwise until you reach reach the top (being sure that the cable is still wrapping neatly). Once you reach the top, the pawl should reset itself and allow you to crank the roof down.
Good luck.

Cable wrapping neatly....what are you talking about?

[AustinBoston]

Cable wrapping neatly....what are you talking about?

He's talking about anything that isn't an obvious jam-up.

Austin

[flyfisherman]

I got underneath the camper and took the cover plate off to try and figure out what was wrong.  There was a nest tangled up in the screw near the block where all the cables attach.  I cleaned the nest out, but the system still doesn't work.  


Thanks,
John

I'm curious as to what kind of a nest that might have been.


Thanks,


Fly

[wavery]

Cable wrapping neatly....what are you talking about?

Good question :p ......Make sure that all of the cables are on the pulleys and haven't slipped off and are jammed. Also, make sure that the cables are straight and haven't gotten all twisted up on the whiffle tree connections :sombraro: .

[Old Goat]

In your original reply, you said, "the cable", and I was wondering which one of the four that you were talking about.....

[jdavino]

Thanks to all for the replies.  I think I need to clarify my situation because some of the talk about cables wrapping neatly on the pulleys may not apply.  The lift system I have looks like a short crank mechanism that is coupled to a long threaded screw.  On the long threaded screw is a block with four eyes.  Each one of the eyes has a cable connected to it.  I'm assuming each cable goes to one of the supports at the four corners of the roof.  

What it looks like is supposed to happen is for the block with the cables attached to it to move along the threaded screw as the crank is turned.  I don't think the cables are supposed to wrap around it.  The problem is that when I turn the crank the screw doesn't keep turning so the block never moves.

I've cut some 2x4's to support the top, and I'm thinking maybe I can disconnect the four cables at the eyes I described above and then try to free up the block so it turns on the screw.  If anyone else has some other ideas I would love to hear them.

Thanks again,
John

[lenwick]

Thanks to all for the replies.  I think I need to clarify my situation because some of the talk about cables wrapping neatly on the pulleys may not apply.  The lift system I have looks like a short crank mechanism that is coupled to a long threaded screw.  On the long threaded screw is a block with four eyes.  Each one of the eyes has a cable connected to it.  I'm assuming each cable goes to one of the supports at the four corners of the roof.  

What it looks like is supposed to happen is for the block with the cables attached to it to move along the threaded screw as the crank is turned.  I don't think the cables are supposed to wrap around it.  The problem is that when I turn the crank the screw doesn't keep turning so the block never moves.

I've cut some 2x4's to support the top, and I'm thinking maybe I can disconnect the four cables at the eyes I described above and then try to free up the block so it turns on the screw.  If anyone else has some other ideas I would love to hear them.

Thanks again,
John

Has the handle come loose a nut come off

[wavery]

Thanks to all for the replies.  I think I need to clarify my situation because some of the talk about cables wrapping neatly on the pulleys may not apply.  The lift system I have looks like a short crank mechanism that is coupled to a long threaded screw.  On the long threaded screw is a block with four eyes.  Each one of the eyes has a cable connected to it.  I'm assuming each cable goes to one of the supports at the four corners of the roof.  

What it looks like is supposed to happen is for the block with the cables attached to it to move along the threaded screw as the crank is turned.  I don't think the cables are supposed to wrap around it.  The problem is that when I turn the crank the screw doesn't keep turning so the block never moves.

I've cut some 2x4's to support the top, and I'm thinking maybe I can disconnect the four cables at the eyes I described above and then try to free up the block so it turns on the screw.  If anyone else has some other ideas I would love to hear them.

Thanks again,
John

I guess my post was more confusing than I thought :eyecrazy: .

You are correct about the long screw and the 4 cables. The part that the cables attach to is called a "Whiffle Tree". I meant, to be sure that each cable wraps (maybe "turns or bends" would be better) around the pulleys correctly and that a cable didn't get jammed somewhere (like between the pulley and the frame).

If the pawl is stuck on the end of one of the teeth on the gear, that may cause the mechanism to free-wheel. If you clean that real good with WD40 and have someone turn the crank clockwise (with the roof supported), the pawl should free up and the screw may start turning.

It sort of sounds like you may have a couple of problems going on at once. Normally, if the pawl gets stuck, the roof will come down out-of-control. However, it sounds like you may have a stuck cable.

It could be possible that there is something messed up in the cranking gears that attach to the screw in the whiffle tree.

[Bowfin]

On my camper (98 Coleman Taos), my pin and coupler was broken that connects the crank to the whiffle tree. New part was around $36 for the coupler and $2.00 for the solid pin.

My symptoms were a spinning crank in both directions and no movement of the top. I had to remove the whiffle tree inspection cover and lower the top by turning the whiffle tree by hand. To fix I had to remove the crank assembly form the camper to install the new coupler and pin. I took the opportunity to relube the whiffle tree and now it's smoooth.

If your crank spins when lowering, but won't budge when raising and your top up, your coupler and pin is fine. You may need to turn the crank clockwise a "click" then lower the top. It should be outlined in your manual.

One thing to note, you can break the crank mechanism by overcranking. On mine it broke the collar and pin, though I believe it was already broken by the PO. It broke the first time I raised my PUP.

[AustinBoston]

The problem is that when I turn the crank the screw doesn't keep turning so the block never moves.

Just to make sure the problem isn't super-easy to fix...

Is the shaft that the crank handle inserts into turning?  It is not hard to put the crank in but not get it to engage the pin.  In that case, you could crank all day long and the lift system will do nothing.

Another possibility is that the pin is broken or missing, or that the shaft has debris in it preventing the crank handle from properly engaging the pin.

Austin

[jdavino]

I've read the last few posts and my problems sounds very similar to the one Bowfin had.  The crank spins in either direction but the whiffle tree doesn't move.  The crank is definitely turning so its not a problem with the handle not engaging and none of the cables appear to be jammed.  I am curious to know what and where the "pawl" is and how I can check it.  

If the problem is the coupling between the crank and the whiffle tree I don't think I want to try to fix it on my own.  I do need to get the top down to trailer it to the dealer.  How can I manually turn the whiffle tree?  Do I just put a pair of channel lock pliers on the screw and twist?  Or is there some other way to turn it?

[wavery]

I've read the last few posts and my problems sounds very similar to the one Bowfin had.  The crank spins in either direction but the whiffle tree doesn't move.  The crank is definitely turning so its not a problem with the handle not engaging and none of the cables appear to be jammed.  I am curious to know what and where the "pawl" is and how I can check it.  

If the problem is the coupling between the crank and the whiffle tree I don't think I want to try to fix it on my own.  I do need to get the top down to trailer it to the dealer.  How can I manually turn the whiffle tree?  Do I just put a pair of channel lock pliers on the screw and twist?  Or is there some other way to turn it?

In you original post, you said that you were able to crank it up but it got hard. Have you tried cranking the handle clockwise enough to take up the slack on the cables? It may get to the point where you have stress against the handle again. If it does, give it one more good crank up. It you have sprayed WD40 up in the mechanism, the pawl may reset itself. If it does, you will be able to crank the roof down.

If it just keeps free-wheeling clockwise, without moving the screw at all, then something may be broken as Bowfin experienced.

You may be able to turn the screw with a pair of channel locks but I would be very careful. I don't know if that top may come down hard once you start turning that screw. I think that I would try turning the screw clockwise real hard first (to try to reset the pawl).

It might be a good idea to have a couple of good strong guys on hand to catch the top if it starts coming down fast. If the pawl is OK and the mechanism is broken, it may well come down normally by turning the screw manually. Just be careful not to mess up the threads on the screw. You might try putting a piece of leather between the channel locks and the screw, if you have to grip the threads.

[Bowfin]

I've read the last few posts and my problems sounds very similar to the one Bowfin had.  The crank spins in either direction but the whiffle tree doesn't move.  The crank is definitely turning so its not a problem with the handle not engaging and none of the cables appear to be jammed.  I am curious to know what and where the "pawl" is and how I can check it.  

If the problem is the coupling between the crank and the whiffle tree I don't think I want to try to fix it on my own.  I do need to get the top down to trailer it to the dealer.  How can I manually turn the whiffle tree?  Do I just put a pair of channel lock pliers on the screw and twist?  Or is there some other way to turn it?

I removed my crank mechanism from the bumper, exposing the end of the whiffle tree. I inserted a small phillips screwdriver into the pin hole to drop the top. Very tedious but it got the job done. You might be able to turn the whiffle tree by hand as there isn't much pressure holding the top up. Now that I lubed my whiffle tree, my top practically comes  slowly down on it's own. I wouldn't use channel locks on the whiffle tree, as you don't want to damage the threads. It needs to be smooth.


When i pulled my whiffle tree cover two big chunks of metal fell out that were part of my coupler and the solid sheer pin ( I have AC).

If you're coupler is intact, I would think you have a broken pin. the pins on non-ac campers are rolled pins, which can break easily if you over crank the top which sounds like what you may have done when trying to get the top higher. If your camper is older, it may have come with rolled pins, even with AC.

One safety consideration to remember, the only thing holding your top up is the clutch on the crank. My whiffle tree had enough "stiction" that the top stayed up even when removing the crank.