Fleetwood Power Lift Remote Repair (picture heavy)

Discussion in 'Miscellaneous Repairs & Maintenance' started by Adam H, Aug 4, 2019.

  1. Adam H

    Adam H Active Member

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    Hello All. Those of you with newer Fleetwoods, Colemans, and Somerset pop ups know all too well the flimsy microphone jack plugs the lift system uses for the remote. Well mine finally broke and I had to manually crank the top up on my last trip. Wasn’t very hard but below are the steps I took to replace the plug with something more robust. Since the plug is integral with the lift controller, the first step was to remove it from the camper for disassembly. Easy, drill the rivets, unplug the motor wires and cut the power wires. My power wires were already on plugs due to a prior modification.
    The original plug must be broken to get the cover off the controller. Here is the controller with the cover off, broken plug visible.
    B0943A04-4EF7-4F29-92F3-1CD3900EA0B1.jpeg

    Once the cover is off CAREFULLY cut the wires out of the epoxy. It’s not hard but be careful.
    F9C284CE-640F-4A72-B858-A2E96FF53096.jpeg

    Here is the cover after I removed it. The hole must be enlarged for the new plug. For this I am using a computer power supply plug. Very robust and 3 connections like the original.
    35CC1395-CD98-497D-B7ED-ABF037C59F18.jpeg

    Here are the wires after I cut them out of the epoxy. Take careful note of the order of the wires!
    F5168A1A-1664-4D4E-9B34-C93E25A6A130.jpeg

    Here is the plug and unmodified cover.
    8A5F6AC0-335E-4026-904B-2119204E9E93.jpeg

    Test fitting the plug after enlarging the hole. Some trimming around the screws will be needed for the spring loaded cover to clear. No worries, still enough left to screw it down.
    15C15586-FDA0-40BA-9960-2A18E8C2CFBA.jpeg

    Small spade connectors for the new plug. If I were to redo this, use 90 degree bent spades for better clearance on reassembly.
    DBAAD2CC-649A-4B26-98E7-C8B5064E5059.jpeg

    Connector trimmed and sealed. I did clean up the sealant.
    58A21ED1-39BF-44A2-8388-AFA5DA45F7A1.jpeg

    Not shown but after resealing the epoxy, I had to bend these connectors 90 degrees. A little sealer around the perimeter except the bottom.
    16E744E2-BDB9-4F7D-95E6-1B0C4793CB9C.jpeg

    To be continued
     

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    Last edited: Aug 4, 2019
  2. Adam H

    Adam H Active Member

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    Plug installed and screwed down.
    6CCF8A68-674B-4FD6-ABC3-423169DAF242.jpeg

    Cover reinstalled and door installed. Cleared the new plug perfectly.
    F1C34439-E3CB-451B-B7E8-9F31C5CAA42B.jpeg

    Time for the remote end.
    FA89B49A-B811-4C84-A6C8-228D9BBC77A3.jpeg
     
  3. Adam H

    Adam H Active Member

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    Phase 2.... I truly thought this would be the easy part but it wasn’t. Those tiny wires were a pain! Remote with old garbage connector next to the new connector.
    02CD2312-B3A6-4FA4-A1A3-3078291B174B.jpeg

    First was to disassemble (break) the old connector. Cut it open and make note of the order the wires are in. Almost as I expected but assume nothing when dealing with campers.
    8B86E57B-C498-424F-A770-B2C1082BF08C.jpeg

    Connector wired up and secure.
    C623350F-7F71-4999-AA12-1923FE3828F2.jpeg

    No all that’s left is to reinstall the controller and test.
     
  4. Adam H

    Adam H Active Member

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    Time to test. First was to connect everything up and try to hand crank it. This verifies the brake is working. It was very hard to crank so all is good there. Now for the real test.
    Plugged the remote in and low and behold it works perfectly.
    DD9C6EC9-721F-4652-BFE0-1E8B5D8D11DE.jpeg

    Looks factory too [A]
    C339315E-6A4C-4E17-9ACA-507FD528FA4E.jpeg

    I hope this helps someone out who would otherwise have to spend $$$$$$ on a new controller with the same crappy plug.

    Adam
     
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  5. Pnut

    Pnut Member

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    Looks better than factory. Great write up and the pictures are a huge help for anyone else who has this problem.
     
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  6. megcabra

    megcabra Well-Known Member

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    Great job, and thanks for sharing your fix!
     
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  7. PopUpSteve

    PopUpSteve Administrator

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    Well done!
     
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  8. Adam H

    Adam H Active Member

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    Thank you everyone. Maybe I should’ve put this in the Lift System forum? Feel free to move it if you wish.

    Adam
     
    Last edited: Aug 4, 2019

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