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Old 07-29-2012, 07:10 PM   #15
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The other side should be looked at too and maybe spot welded when the crack is repaired in case that side is weakened. A good welder should be able to make it plenty strong (note the adjective "good" before welder).

If shear bolts don't shear, something is wrong. The crack happened before the shear bolt design failure point and my guess is the broken area has a design defect or contaminated metal. On a short thread, there are already one and maybe two posts about the same thing.

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Old 07-30-2012, 08:59 AM   #16
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Wow. I thought these things were pretty much bulletproof.
I'm surprised the torsion bar doesn't drop out.
How old/approximate mileage on that?

I used to ratchet up the struts to max, with no holes showing... after talking with Aaron, he said the reason they don't recommend doing that is possibility of the torsion bar bracket hooking onto the strut bar bracket underside... but I'm wondering if this is another reason not to?
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Old 07-30-2012, 10:33 AM   #17
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Sounds like its time for a new Andersen WD. Have none of those type problems with mine, and it's light as a feather . No, this hitch probably works great for you, but something isn't working right if that crack happened you need to talk to them and figure it out, or it will probably happen again.
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Old 07-30-2012, 11:50 AM   #18
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Well, THAT got me up off the desk chair in a hurry. Glad to report all is well on ours, but THANKS for making me look. Hensley replaced our Orange Part this year at no charge after the hitch ball weld separated a bit. That's the next thing to look at when you nice and level and can un-hitch easily.
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Old 07-30-2012, 11:04 PM   #19
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Talked to Terry at Hensley before the welder came this morning and sent him pictures. He said that having somebody else do the repair won't affect the warranty. Discovered that the bushings where the spring bars attach was broken too, but on opposite side from the weld break? Hensley will send me new bushings. On the road home and so far no further problems. The bushings look pretty worn to me. About 40K of towing on the hitch.
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Old 07-30-2012, 11:20 PM   #20
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.....................


The bushings look pretty worn to me. About 40K of towing on the hitch.
That sounds like of bunch of towing miles. Over what time span was that? I guess we don't use our trailer enough.
Is the eccentric shape of the inside of bushings wear or are they designed that way?

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Old 07-30-2012, 11:26 PM   #21
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I think they were round originally. Those miles are since 9/06 and I wish I could spend more time in it.
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Old 07-31-2012, 05:54 AM   #22
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The bushings are originally round and are considered a wear item. I replaced them in my hitch during refurbishment. A simple but dirty, greasy job.
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Old 07-31-2012, 07:18 AM   #23
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May I ask a couple of questions from those who have seen the cracking?

1) At what mark on the jacks do you keep the bars cranked up to?
2) Are these 1000# bars?
3) Do you recall ever going through a rather deep "hoop-de-doo" or a steep driveway entrance?

To me the area of the crack (and the broken bushing) indicate a large stress due to an upward pressure at the bar ends, opening the bottom of the bushing bore. I'd really like to try and prevent this from happening to mine.

Yes, the bushings are a wear item and are replaceable, unlike some other hitches where you replace the whole head when the bar sockets get worn. I carry a bushing set in my spare parts bag.
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Old 07-31-2012, 07:31 AM   #24
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Further to the questions above.

Others have had their bushings break similar to the pictures you are showing here. I'm wondering if the bushing had broken first and be undetected could that place additional stress on the weld of the head?

Also wondering if you have excessive wear showing elsewhere - the holes in the jack extensions come to mind - I think it is typical for them to wear slightly oval - but if you had some single event that contributed to this break then could they also show some excessive stretching?


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Old 07-31-2012, 08:24 AM   #25
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Good points.





The last time I was at the Romeo warehouse, I showed Dennis the holes in the black head (where the bushings go) had ever so slightly elongated, along the axis of weight distribution. He was adamant that was not an issue... I would submit, Cahalan's failure says otherwise.
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Old 08-01-2012, 04:03 PM   #26
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Originally Posted by cahalan1526 View Post
Here are a couple pics. You can see the light coming through. There is no load on it at this point. I don't know if it would separate further under load.
You Hensley owners probably don't want to hear this, but this thread got me to thinking, so I went out and checked the same areas on my ProPride, and it has substantially more metal and strength there. I feel better now.
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Old 08-01-2012, 05:05 PM   #27
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You Hensley owners probably don't want to hear this, but this thread got me to thinking, so I went out and checked the same areas on my ProPride, and it has substantially more metal and strength there. I feel better now.
Regardless of any comparison with ProPride I would find it tough to believe that this failure is a design issue. There have been a ton of folks to ponder the merits (or not) of my own Hensley and I've never heard anyone comment that it looked like it was under engineered. Having said that - the design and construction are not simple - and it would be good to bring the cause of this failure to ground - design is certainly one factor not to be ignored - but more logical factors that come to my mind might be: a bad weld, wear, something missed in the set-up or some kind of event that stressed the joint way beyond the norm.

It would be great to have the folks from Hensley jump in here ..... if they've never seen this kind of failure before that would be good to know ..... if they have and they know the typical circumstances of the failure that would be also good to know.



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Old 08-01-2012, 05:18 PM   #28
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You Hensley owners probably don't want to hear this, but this thread got me to thinking, so I went out and checked the same areas on my ProPride, and it has substantially more metal and strength there. I feel better now.
SteveH, if convenient, put a pic up. Tnx

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