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Old 07-29-2012, 01:32 PM   #1
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Weld broke on Hensley

Went to hitch up this morning to head back to AZ. When I was greasing up the Hensley I noticed that the weld around the W/D bar connection was cracked. Further inspection shows about a 4" crack (can see through it). Will be spending at least another day in Rapid City to get it welded. Lucky I found it before I left, but I wonder when it cracked. Didn't notice it the last time I hitched.
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Old 07-29-2012, 01:46 PM   #2
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Pix, please!
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Old 07-29-2012, 02:02 PM   #3
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Thanks for this important information. I have a Hensley that is six years old (#8332) that has almost 100,000 miles of towing on it. I will be giving it a thorough inspection. Pictures of your broken weld would be great.

Brian
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Old 07-29-2012, 03:28 PM   #4
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Quote:
Originally Posted by cahalan1526
Went to hitch up this morning to head back to AZ. When I was greasing up the Hensley I noticed that the weld around the W/D bar connection was cracked. Further inspection shows about a 4" crack (can see through it). Will be spending at least another day in Rapid City to get it welded. Lucky I found it before I left, but I wonder when it cracked. Didn't notice it the last time I hitched.
Pat, we found a good welder in Union, Nebraska a week ago. I know when my hitch cracked because I did it. ;-(

We will be headed out of Gunnison tomorrow, headed home after 2 months on the road. Travel safe and we will see you soon!
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Old 07-29-2012, 04:33 PM   #5
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Pictures

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.
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Old 07-29-2012, 04:50 PM   #6
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dont know what caused the crack but from the paint flaking it looks like you may have stretched or separated more of the weld running back under the hitch body. Have your welder take a good look while he's there.
tim
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Old 07-29-2012, 04:58 PM   #7
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Thanks, I'll have him check it out. The paint came off when I was cleaning the crack and picking at it to see the damage.
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Old 07-29-2012, 05:29 PM   #8
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Thank you so much for the pictures. I'll be all over Lucy's Hensley as soon as possible.

Brian
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Old 07-29-2012, 05:31 PM   #9
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Aren't these hitches guaranteed for life against this kind of failure?????
I'd be scared $&!#-less to just weld it back togeather and continue using it!
What caused that failure? I would certainly be on the phone to Hensley looking for advise....
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Old 07-29-2012, 05:51 PM   #10
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I, too, think you should check with Hensley.

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Old 07-29-2012, 06:00 PM   #11
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Yes it has a lifetime warranty and I would send it back to them for a replacement. I would call them in the morning before you get it welded though.
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Old 07-29-2012, 06:22 PM   #12
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I had the same crack on mine. Hensley replaced the head under the Lifetime Warranty. You don't have to pay to have it welded unless you're in a hurry or don't want to incur shipping costs.

All hitch owners should inspect their gear including tow vehicle receiver, regularly. No brand is immune to wear and tear!
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Old 07-29-2012, 06:24 PM   #13
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Disclaimer:
I am not trying to start an argument.
I am not trying to suggest a cause.
I am simply curious.

Would this be a point of stress if a turn was made that was tighter than the hitch design would allow?

Ken
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Old 07-29-2012, 06:37 PM   #14
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I've already emailed Hensley and will call first thing in the morning. They do have a lifetime warranty and have always treated me well on the few minor issues I've had. I do have to get home for some prior commitments, plus with Sturgis coming up the campgrounds are full. As to the stress point question, my understanding is that the shear bolts on the a-frame are supposed to give when it is turned too tight. Thanks for the advice and I'll keep you posted.
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