worn cables

Submitted: Thursday, Feb 15, 2007 at 21:29
ThreadID: 42360 Views:2094 Replies:7 FollowUps:5
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Could anyone tell me how hard it is to replace cables in a Jayco Dove pop top? I have replaced a worn pulley/bearing system after noticing one cable was starting to fray. How hard is it to replace??
Cheers Newby
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Reply By: Bilbo - Thursday, Feb 15, 2007 at 23:30

Thursday, Feb 15, 2007 at 23:30
Newby,

I've never done this job myself or had it done, but some good mates of mine had a Jayco Hawk Outback cabling done last year. From what I remember, it cost $2500.00.00! It was a bitch of a job from I what I was told.

That's another reason I won't touch a wind up camper,,,,,,,,,,,

I can find out for sure what the cost was if you like.

Bilbo
AnswerID: 222001

Reply By: Pajman Pete (SA) - Friday, Feb 16, 2007 at 08:04

Friday, Feb 16, 2007 at 08:04
I have had mine apart on our '84 Dove when one of the bolts on the swash plate came loose and one corner did not go up! Not a recommended job at a camp ground. When I got home I opened up the system and checked it all out. Getting to the front ones is not too bad but running new cables to the rear would be painful - the access is not good, but you may be able to pull them through with the old cables.

One other thing to check out. On the older doves like mine the winch is bolted into the plywood floor, not the frame, on at least 2 of the bolts ( I can't remember now!) I have fitted metal brackets to the frame on mine to strengthen this area.

If you are going to get new cables made up, take the old ones to a yacht supplier and get them to make up new stainless cables with the fittings. It will be a lot cheaper than you imagine, they sell stainless cable my the kilometre and the terminations are cheap as well. About 1-2 $ a metre depending on thickness and $4 a termination.

Cheers

Pete
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AnswerID: 222034

Reply By: traveller2 - Friday, Feb 16, 2007 at 08:39

Friday, Feb 16, 2007 at 08:39
At least the pulleys etc are/should be commonly available bits as it is Aussie made.
Yeasr ago I helped a friend rebuild the sytem on his Coleman camper, the pulleys etc were all imperial non standard sizes and we had to make new brackets etc to fit locally available bits. A real nightmare!
AnswerID: 222042

Reply By: Member - Franga (QLD) - Friday, Feb 16, 2007 at 08:42

Friday, Feb 16, 2007 at 08:42
Hey Newby,

Try this site link it may be of help
Site Link

Cheers with Beers

Franga
AnswerID: 222043

Reply By: allan b - Friday, Feb 16, 2007 at 10:48

Friday, Feb 16, 2007 at 10:48
Did rear cables in stainless a couple of months ago took a bit of time no real problems though. It was a Jayco penguin.
AnswerID: 222063

Follow Up By: Newby - Friday, Feb 16, 2007 at 11:21

Friday, Feb 16, 2007 at 11:21
Allan, did you have any diagrams/schematics to follow?
Reg Newby
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FollowupID: 482856

Reply By: Newby - Friday, Feb 16, 2007 at 11:22

Friday, Feb 16, 2007 at 11:22
Thanks for the tips. I sorta knew it would be a tough job but may spend a couple of days in the workshop to figure this out.
AnswerID: 222071

Follow Up By: Member - Franga (QLD) - Friday, Feb 16, 2007 at 13:33

Friday, Feb 16, 2007 at 13:33
Hey Newby,
I completely stripped and rebuilt our Jayco swan back in 93 I'll have a look to see if i took picy's of the cable setup and post them if I find them.
When you do the job make sure you use plenty of grease on the nylon slides where the spring runs to go up into the roof struts.

Cheers with Beers

Franga
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FollowupID: 482877

Follow Up By: Member Dublediff(VIC) - Friday, Feb 16, 2007 at 16:22

Friday, Feb 16, 2007 at 16:22
I wouldn't use grease, it collects dirt and all that crap and pushes it up the roof strut. Use plenty of wd40 or similar and keep a tin in your tool kit. Every so often give the struts a good spray, protect canvas, and this will ensure easy running. An old jayco mechanic gave me this tip....
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FollowupID: 482907

Follow Up By: allan b - Friday, Feb 16, 2007 at 16:24

Friday, Feb 16, 2007 at 16:24
Newby, Just used the old cables to measure new stainless ,hardest part was finding out where cables were located ,cost about 35 dollars for cable and swages and made them up myself, most marine places will lend you swageing tool.
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FollowupID: 482909

Reply By: Newby - Friday, Feb 16, 2007 at 17:31

Friday, Feb 16, 2007 at 17:31
Thanks heaps for the replies. Until I pull it apart I can't picture how the cable lift system lifts the arms up?? So any pictures/diagrams would be appreciated I have only just purchased the Dove but found a aerosol can of chain and cable lubricant is very good, expensive though, sold by John Deere for their headers.
AnswerID: 222136

Follow Up By: Newby - Saturday, Feb 24, 2007 at 10:10

Saturday, Feb 24, 2007 at 10:10
Just finished replacing rear cables. Cost $54 for cable and replacement pulley. Not a real hard job for anyone considering doing it themselves. However the sink and has been removed from this Dove van making access easier.

Cheers Newby
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FollowupID: 484553

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