How do i lubricate winch on Jayco?

Hi janset
For seven years we have had ultimate camper.
Prior to that we have had two windup jaycos.
The last was an off road swan.
The symptoms you describe are similar to the swan where the rear cables to elevate the roof snapped.
We were making camp at the mitchell plateau and two winds of the handle and down came the roof, and thats where it remained for another three weeks.
After the cables leave the winch they make a sharp right angle turn and travel through rhs tube to the back of the camper.
There is a nylon pulley where the right angle turn is and the wire rope cuts through the pulley until it reaches the bolt through the centre.
The radius is small and allows the cable to rub on the edge of the rhs slowly making it fray into what looks like tangled fishing line. This is what caused the stiffness in the winch.
The cables wore through strand by strand and eventually snapped.
I had lubricated the winch before hand and made no difference.
Suggest you do a bit of dismantling on the front right hand side and have a look at the cables.
Stan

early model jayco campers had a different setup to the later ones so not sure which is yours. anyway just need to get inside, take off the ply backing on the other side of your winch and have a look at whats happening.

but before you do maybe worthwhile you do a google search for a maintenance manual on jayco campers written by Trevor Eastman "Book 2 Service & Repair Manual JAYCO" and get a copy (around $35 to 40) its very handy as it explains all the workings of your camper, owner maintenance, and also explains how to fix any of the bits you may break over time.

someone on here at EO found a link to a site selling the manual last year so you should be able to find it. i have a copy and it is very detailed probably around 70 pages. BTW, dont use grease. You can use some silicone spray on the risers/uprights but cover the cavas behind it first. also use same on the cables inside when you get to them. (buy the manual you will find it very helpful)

Hi guys. Thanks for your replies.

My Jayco is a 13 foot Penguin and was purchased new October '02.

As to the publications, I have a very good one put out by Trevor Eastman called Camper Care. He does a great job in explaining all the tips and tricks on how to do things on the Jayco and _Affordable_Storage_Drawers.aspx diagrams so you know what to expect to see and how the faults occur, including the cable wearing though the tubing as mentioned.

But, (there is always a but), no where that I can find in this excellent publication does he mention how to, or with what the winch should be lubricated.

I agree that I should pull the covers off and check things out and I will be doing this.

So until I am told otherwise I guess it will be only silicon spray used everywhere so as not to collect dust. but I am still concerned as to what care I should take with the winch clutch during the lubrication process.

Unfortunately I have not been able to find an email address for Trevor Eastman to ask him. I have his address and phone number, I guess I may have to write to him snail mail as an STD phone call from Perth to the Eastern States could work out costly should I be put on hold.

If there are any further suggestions, please post.

Regards

Sorry guy's I have never seen the winch design on these things.

But if the cable is cutting the plastic wheels or puleys then fraying! then there should not be any plastic wheels or pulleys to do the damage in the first place.

Then again what if you used spectra rope now thats a kinda plastic and stronger than cable with little stretch, and I don't think that will tear up the pullys either.

They use this spectra rope on boat winches most swear by it !but I prefer me boat strap as it's better on the hands.

Hi guys.

Just an up date. I have half the work done. I pulled every thing out at the rear end of the Jayco and checked everything out.

All look O.K. on the mechanical/cable side of things but I did find something that I think would have to contribute to a stiff wind up/down problem.

The 'rocket scientist' the installed the fascia box that covers the cable and pulley system, when bolted in place, no aperture was cut to allow the cables to pass freely from outside of the enclosure box to the inside.

The end of the fascia box on the RHS was jambed hard up against the cables which in turn were pushed hard up against the inside wall of the van.

After removing the box and upon inspection I could see where the cable had actually BURNED the wooden frame of the enclosure box.

In effect this would have acted as a brake when winding up or down.

In the next few days I will tackle the front half and see what other surprises they have install for me.

Regards