Falcon 5250 complete repair kit

part number 910003-55

This kit contains the components to replace the Falcon 5250

Autowlok™ button assemblies, collar shoulder bolts, inner and
outer arm bushings, washers and end plugs.
Towing and Suspension Solutions
855010-02 08-14 All specifications are subject to change without notice.
ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 800-669-9690 Fax: 360-735-9300 www.roadmasterinc.com

Read the instructions before installing the

kit components. Failure to understand how
to install this product could result in prop- Figure 1
erty damage, serious personal injury or even
death.

IMPORTANT!
Before you begin the installation…
Check the serial number before beginning the installa-
tion. The serial number is located
on the passenger side tow bar arm Figure 2
(Figure 1).
If the serial number is 23240
or lower, you must use different
outer arm bushings from those
included in this kit. Discard the
two supplied bushings (Figure 2)
and order two replacement bushings, part number 200031-
00.
Kit components
This kit contains the components to replace the Falcon
5250 shoulder bolts, bushings, washers and end caps —
IMPORTANT NOTICE! (2) shoulder bolts (2) Nylock nuts
Safety Definitions (2) ¾" locking nuts
These instructions contain information that is very im- (6) 1½" diameter acetyl washers
portant to know and understand. This information is pro- (4) ¾" diameter acetyl washers
vided for safety and to prevent equipment problems. (2) end caps (2) rubber ‘bump ons'
To help recognize this information, observe the following This kit also contains the components to replace the in-
symbols: ner and outer tow bar arm bushings and Autowlok button
assemblies —
(2) 1¼" acetyl inner arm bushings
WARNING indicates a potentially hazardous situ- (2) outer arm bushings (2) button stems
ation which, if not avoided, could result in property (2) Autowlok buttons (2) springs
damage, serious personal injury or even death. (2) pins (1) epoxy glue kit

Required tools
CAUTION indicates a potentially hazardous situ- 1¼" socket wrench crescent wrench
ation which, if not avoided, may result in property putty knife or scraper 9/16" socket wrench
damage, or minor or moderate personal injury. ¼" Allen wrench straight edge screwdriver
pen knife felt tip pen
CAUTION grinder rubber mallet
CAUTION used without the safety alert symbol pliers or channel locks
indicates a potentially hazardous situation which, if
not avoided, may result in property damage.
To aid in reassembly…
…carefully note: the position of the driver’s and pas-
NOTE
senger’s side tow bar arms, in relation to the yoke (Figure
Refers to important information and is placed in italic
3); the location of the two 1½" diameter acetyl washers on
type. It is recommended that you take special notice of
the stinger bolt (Figure 4); and the location of the four 1½"
these items.
diameter acetyl washers on the yoke bolt (Figure 5).
 Installation instructions Figure 3
Replace the stinger washers and nut
1. Work on one tow bar arm at a time.
With a 1¼" socket wrench and a crescent wrench,
remove the stinger bolt (Figure 6). Discard the two original
1½" diameter acetyl washers and the ¾" nut; replace them
with new washers and a new nut. Reattach the bolt.

Remove the yoke bolt, washers and nut

2. Using the same wrenches, remove the yoke bolt (Figure
5). Discard the four original 1½" diameter acetyl washers and
the ¾" nut; later, you will replace them with new washers and
a new nut.

Replace the inner and outer arm bushings

3. With a straight edge screwdriver, pry off one of the
square black dust caps (Figure 1).
4. Use a felt tip pen to mark the tow bar arm at the point
where the round nut (Figure 7) attaches to the end of the
tow bar arm.
5. Using a 9/16" socket wrench and a ¼" Allen wrench,
remove the collar shoulder bolt (Figure 7). Discard the bolt,
Nylock nut and the two ¾" diameter acetyl washers.
Unscrew the round nut (Figure 7) and remove it from
the end of the inner arm. Figure 4
6. Wrap a cloth around the end of the outer arm. You will
use this cloth to catch the Autowlok assembly as it clears the
outer arm. Then press the Autowlok button (Figure 1) down
and push the inner arm out of the hole created by removing
the square black dust cap.

The spring is under pressure and will eject the pin

when the spring assembly clears the outer tubing. To
avoid personal injury, wrap a cloth around the end of
the tubing and stand to one side, clear of the pin, as the
Autowlok assembly clears the outer tubing.

Push the inner arm completely out.

7. Remove the old bushings — both the 1¼" diameter acetyl
inner arm bushing (Figure 8) and the outer arm bushing
(Figure 2).
8. Clean the interior of the outer arm with a water-soluble Figure 5
continued on next page

Figure 6
Figure 7
continued from preceding page Figure 8
cleaner such as Voom RV (part number 9911) — spray a
liberal amount of cleaner inside the arm, then push a piece
of cloth through to the other side. Repeat, if necessary, until
the interior of the outer arm is clean.

CAUTION
Do not use petroleum-based products to clean or lu-
bricate the tow bar. Petroleum will attract dirt and dust,
which will impede the operation of the sliding inner arms
and/or other components. Certain petroleum products
may also corrode non-metallic components.

9. Inspect the surface at the round end of the outer arm

(Figure 1), where the new outer arm bushing will be attached.
If there is rust or corrosion, use extra fine (0000) steel wool,
3M “Scotch Brite” (fine pad) or a similar product to remove
it.
10. Before attaching the new bushing, rinse the interior of the
outer arm to remove all of the cleaner (and metal shavings,
if you sanded the interior).
Dry the interior of the outer arm completely, by repeatedly Figure 10
pushing a piece of cloth through to the other end.
11. Follow the instructions on the supplied package of epoxy
glue to mix and activate the glue. Figure 11
Note: the epoxy glue will be used four times. Either mix a
quarter for each application or substitute black ABS cement
(not supplied).
Apply a light coat of glue around the outside of the new
bushing and, within 30 seconds, slide it into the round end
of the outer arm until it is flush with the hole.
Note: this is an extremely tight fit. It will require substantial
force to fully insert the new bushing.
Note: the epoxy glue will be cured in 24 hours, but it will
be set in 10 minutes. Allow the glue to set for at least 10
minutes before towing. Turn the tow bar arm over and move the inner arm for-
12. Fit one of the 1¼" diameter acetyl inner arm bushings ward or backward slightly, if necessary, until the button stem
(Figure 8) onto the raised lip at the end of the inner arm (Fig- drops through the hole in the outer arm. Then draw a straight
ure 8). Then, test the fit — slide the inner arm into the outer line with a pencil across the bottom of the inner arm (Figure
arm. 10), ¾" from the edge of the outer arm.
Note: if the 1¼" diameter acetyl bushing is too wide to fit, Slowly close the inner arm until the edge of the outer
use a grinder to trim a small amount from the edges touching arm is even with the pencil line you drew. This position will
the inside of the outer arm. Trim an equal amount from each stabilize and support the button stem.
side, test-fit the bushing and trim more, if necessary, until the 14. Remove the old Autowlok button (if present) with pliers or
inner arm slides in and out easily. channel locks, being careful not to scratch the button stem.
15. Turn the tow bar arm back over and clean any dirt or
Attach the Autowlok button assembly debris that may be on the exposed surface of the button
13. Replace the button stem — first, with the old pin and stem.
spring (Figure 9) removed, Note: for easier attachment to the button stem (step 16,
insert the new button stem Figure 9 below), drop the Autowlok button in boiling water for five
(Figure 9) flat side up into minutes. The heat will make the button more flexible.
the opening at the end If you choose this method, dry the button completely
of the inner arm opposite before applying the glue.
the 1¼" acetyl inner arm 16. As before, follow the instructions on the package of
bushing. epoxy glue to mix and activate a portion of the glue (or sub-
Then slide the inner stitute black ABS glue), then apply enough to lightly cover the
arm into the outer arm until inside of the button. Next, apply enough glue to completely
the top of the button stem fill the grooves at the top of the button stem.
is visible through the hole Within 30 seconds, position the button over the top of
in the outer arm. continued on next page
continued from preceding page Figure 12
the button stem and tap the button down over the button
stem, as far as it can go, with a rubber mallet.

Ensure that the button is tapped completely down, as

far as it can go. If the button is not completely down, it
will not depress the pin and spring far enough to lock
or unlock the tow bar arm.
Both tow bar arms must be locked before towing. If
they are not, the momentum of the towed vehicle will
apply excessive force to the tow bar arms and other
components of the towing system, which may cause
the towing system to fail, resulting in property damage,
personal injury or even death.

17. Allow 24 hours for the glue to set. The button can be
depressed and released after approximately 10 minutes, but
do not pull on the button for 24 hours.
18. After the button has been attached, slide the inner arm
out.
19. Replace the spring and pin — first insert one of the sup- Figure 13
plied springs (Figure 9) into the opening at the end of the
inner arm opposite the flat white bushing.
Then lubricate the flat side of one of the pins (Figure
9) thoroughly — use a dry silicone aerosol, such as Lube-
Master (part number 747). Then insert the pin into the
hole at the end of the inner arm, so that the rounded end
of the pin faces up (Figure 11).

CAUTION
Do not use petroleum-based products to lubricate
the tow bar. Petroleum will attract dirt and dust, which erty damage, personal injury or even death.
will impede the operation of the sliding inner arms and/
or other components. Certain petroleum products may 22. With a ¼" Allen wrench and a 9/16" socket wrench,
also corrode non-metallic components. reattach the collar ear to the round nut. Replace the original
shoulder bolt, Nylock nut and the two ¾" diameter acetyl
Figure 9 shows the 1¼" acetyl inner arm bushing, spring washers with the new components from the kit.
and pin correctly positioned below the Autowlok button and Torque the shoulder bolt to 45 ft./lbs.
button stem. Note: over-tightening the shoulder bolt will bind the col-
20. Insert the inner arm back into the outer arm. When the lar and prevent it from pivoting properly. When it is tightened
inner arm is fully inserted, the Autowlok button will snap into correctly, the collar should pivot easily.
the locked position. Note: the swivel ears (Figure 13) must be attached
with the top facing up. To distinguish between the top and
Replace the collar shoulder bolt, washers and nut bottom, spread the tow bar arms about 28 inches apart.
21. Screw the round nut back onto the inner arm, up to the Place a swivel ear over a round nut and rotate it to the
mark you made in step 4. Make certain that the round nut is left or the right, to the approximate position it would be
not forward or backward of the mark. in when towing. When the top is facing up, the swivel ear
If the round nut is forward of the mark, the replacement will be at the same angle as the tow bar arm.
shoulder bolt will not fit. If the round nut is backward of the
mark, it will rotate off the tow bar arm. Refer to Figure 12.
If the swivel ears are not attached as described
above, the weight of the towed vehicle will cause them
If the round nut is moved backward on the tow bar to separate, resulting in tow bar failure and the loss
arm, the shoulder bolt will not hold the round nut in of the towed vehicle.
place. Towing vibrations will cause the round nut, and Failure to attach the ears properly may cause prop-
the swivel ear with it, to rotate off the tow bar arm. erty damage, personal injury or even death.
The tow bar arm will detach from the towed vehicle,
causing the towed vehicle to separate or to be held 23. Replace the square black dust cap you removed in
by only one tow bar arm, which will result in prop- continued on next page
continued from preceding page
step 3 with one of the new ones.
24. With a putty knife or scraper, pry off the rubber ‘bump on'
(Figure 14). With a cleaner such as Voom RV (part number
9911) remove any residue.
25. With a pen knife, separate the two new ‘bump ons,'
peel the backing strip on the bottom of one and press it into
place.
26. Repeat steps 3 through 25 for the other tow bar arm.
27. Reattach the tow bar arms with the original yoke bolt,
four new 1½" diameter acetyl washers and a new ¾" nut.
Tighten the nut until the bolt is snug.
The torque required to adequately tighten the yoke bolt
varies from tow bar to tow bar. If the bolt is over-tightened,
the tow bar arms will not pivot easily. If this is the case, adjust Figure 14
the torque.

Use all mounting hardware and parts necessary to

replace all kit components and reassemble the tow bar
as described above.
Failure to use all kit parts or to reassemble the tow
bar correctly may cause the tow bar to fail, which may
cause a loss of vehicular control, a traffic accident or
loss of the towed vehicle, resulting in property damage,
personal injury or even death.
 910003-55
Falcon 5250 complete repair kit
This kit contains the components to replace the Falcon 5250
Autowlok™ button assemblies, collar shoulder bolts, inner and
outer arm bushings, washers and end plugs.