7/10/17: We hit the road that morning with the goal of getting to southern Utah for the night. Everything was going fine around town but then, not long after getting out of the Phoenix area heading north on the I-17 the camper starts swaying a lot. For the next 3 hours we experienced the most white-knuckled drive of our lives, I don't know if 10 words were spoken. The weather was kind of bad and the wind and rain weren't helping. Around Camp Verde I was going 45mph just to try and calm the sway down.
Somehow we survived and arrived in Flagstaff. I stopped to get gas and a stranger at the pump next to me starts complimenting our camper. I tell him about how it just tried to kill us and he crawls under it to take a look and points out that I have a broken leaf spring! He also tells me about a great trailer repair shop in town (P&M Trailers).
So I head on over to my buddy's house and tell him about the sway. I show him the leaf spring and then I also show him the Harbor Freight hitch extender that I put on so that I can run the spare tire on the back of the Montero with the camper attached. There is a ton of play at the extension and he's blown away by how I let that slide but the thing is I had been towing the camper all over town and on the freeways for over a month without any sway so I figured I was good to go. Anyways, I removed the spare tire, put in the camper, and haven't tried running the extension since.
Now before you focus on the fact that it was a Harbor Freight hitch extender, I have subsequently checked out hitch extensions by tons of brand and they are all the same. It makes no sense. The extension piece fits into the receiver but not tightly, there's like 2mm of extra space. 2mm or so doesn't seem like a lot by multiple that by an 18" arm and then add the play on the 2nd hitch piece (the one with the ball) and its length and you've got sway city. I seriously have no idea why companies make these hitch extensions because they are all death traps and it makes even less sense when the receiver is a known size so I don't know why they can't make it a tight fit. I've since spoken to several folks about it and most people seem to weld washers or varying sizes on the side of the extensions to take up the slack. I haven't tried this yet as I'm too terrified to even use the extensions now.
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My buddy and I tow the camper over to the recommended trailer store and they tell me that we could probably continue on with our trip with the broken leaf spring and probably be all right since the leaf was trapped by a piece of the frame and wasn't in danger of shooting through the floor of the camper or taking out a section of the wheel well. But they said it was probably not helping the sway since one side of the camper had different suspension dynamics than the other. They determined that I needed 28" leaf springs but they were sold out of that size, and they only had 1 27" spring, so we had to go with 26" springs.
It took the rest of that afternoon and then a good part of the next day to finish the job since neither of us had ever done leaf springs before, we were working in the street, and I didn't have access to all of my tools.
Inspecting the situation:
Working on the situation:
Here's a pic that shows the old spring pack with the broken leaf and the replacement unit:
Bonus result - the shorter springs acted as a lift, raising the body significantly which really came in handy many times on our trip. Here's a pic that shows the new ride height. As you can see, the camper is perfectly level with the Montero even though the Montero is on 33" tires. The camper's wheels should be tucked into the wheel wells but they are almost totally exposed now.
After losing 2 days of travel we decided that Olympic Natl Park would have to wait. It was already going to be a tight trip with long days of driving and now I just felt like resting for a bit and not driving so much. So we decided to scrap the 4,000+ journey and stay in Flagstaff for a few more days and come up with a shorter route.
To celebrate our successful fix, we spent that afternoon picking/eating wild blackberries and swimming in the Oak Creek.