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Old 07-09-2015, 11:06 AM   #1
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Falcon 2 Rebuild

Has anyone rebuilt thier Falcon 2 using the rebuild kit? How difficult? Thanks!

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Old 07-10-2015, 09:37 AM   #2
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Not too hard if you have good tools. The large bolts and nuts aren't going to come loose without long handle wrenches. Socket wrenches are even better and a bench vise comes in handy as well.

Carter with Patty from Kirkland, WA
'05 Alpine Limited 36FDTS + '13 CR-V
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Old 07-10-2015, 10:40 AM   #3
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For $75 roadmaster will do it for you in Vancouver.
Bev & Dick and Fuzzy the cat
2005 Safari Cheetah 38
2009 Honda CRV dinghy
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Old 07-10-2015, 02:52 PM   #4
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Most of the extendable tow bars are about the same in complication or, mechanism. While I've not had the opportunity to rebuild any Roadmaster Falcon models, I've had both my Blue Ox Aladdin and, Blue Ox Avent II completely apart, down to the last nut, bolt and roll pin.

The locking mechanisms are actually very simple in operation. The only stumbling blocks were knocking the roll pins out. They can get stubborn if they want. My last one, the Aventa II, one of the outside tubes was slightly bent so, I straightened it out and, had to weld up a couple of feet that were drug along the road 'till the owner got the rig stopped.

After all the repairs were done, I had all the appropriate pieces powder coated and, then as I was re-assembling it, I installed a brand new shim kit. Now, it's better than new. I've got a whopping $60.00 into that one.

If you've got any DIY in you, you'll have no problems what so ever in rebuilding that tow bar. You'd be amazed at how simple they are.
2004 ITASCA HORIZON 36GD, 2011 GMC Sierra 1500 4x4 Toad '08 GL 1800 Gold Wing
Retired-29.5 yrs, SDFD, Ham - KI6OND
Me, Karla and the Sophie character, (mini Schnauzer)
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Old 07-10-2015, 05:58 PM   #5
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I rebuilt our Falcon 5250, which predates the Falcon2. I purchased all the parts I needed from eTrailer.com. The nut within the main knuckle was a SOB to get off. It took a large long wrench and a bench vise after sitting in penetrating fluid for a week. The rotation movement of that joint had rusted tight and needed major cleaning and lube. Roadmaster has excellent manuals.

The rebuild turned out fine. The area that took some serious machining repair was the pin joints at the arm ends. Both at the car end and at the RV knuckle end. Those large pin holes had enlarged from years of use and remained sloppy after the rebuild. Either I had to replace the parts or machine the holes larger and install bushings in the holes. I chose to install bushings. Roadmaster stated that movement within a joint of more than 1/16" was considered too much. I think that's too conservative, but I had more movement than their spec so it needed to be fixed.
Bob Flight, Rochester, NY- '02 Travel Supreme
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