Replacement Inner Arms for Roadmaster Falcon All-Terrain RM-522  

Question:

Helpful Expert Reply:

If both of the arms are bent in towards the center then it is possible that the vehicle being towed exceeds the capacity of the tow bar, which is 6,000 pounds, or the inner arms may have not extended all the way causing the vehicle to push forward which would push them in some but then they would bend.

If they are bent outward instead then the only thing I can think of that would cause this is if you kept the steering wheel locked on the towed vehicle causing the front wheels to drag and put more force on the arms.

The inner arms are replaceable. For a single inner arm use # 910021-65. There is no left or right so you can use the same arm for either side. Installation is not that difficult. Below are the instructions:

1. Use the straight edge screwdriver to pry off the square black end cap (Figure 1) at the end of the outer arm. Save the cap; you will replace it when the tow bar is reassembled.

2. With the 1/4" Allen wrench and the 9/16" socket wrench, remove the Nylock nut from the bottom of the Allen head shoulder bolt connecting the swivel ear to the round nut. Discard the Nylock nut.

3. Unthread and remove the round nut.

4. Rotate the tow bar arm up, until it is vertical, and slide the inner arm completely out. Note: if the inner bar arm is bent, cut the bent section with a hacksaw or a cut off wheel before pushing the inner arm out.

5. Insert the replacement inner arm back into the outer arm, so that the anvil is aligned to the top of the tow bar. Slide the inner arm completely through the outer arm until it locks in place.

6. Thread the round nut onto the replacement inner arm, until the curved radius at the end of the inner arm aligns to the hole through the round nut. Reinsert the shoulder bolt. If the collar is overtightened, the shoulder bolt will not fit through. If this is the case, loosen the round nut just enough to allow the shoulder bolt to be fully inserted through the collar nut. Do not rotate the round nut forward or backward from this position. If the round nut is moved forward, the shoulder bolt will not fit. If the round nut is moved backward, it will rotate off the tow bar arm.

7. Determine which version of swivel ears are on the tow bar - the swivel ears were redesigned in 2014, to fit either side of the tow bar.

8. For earlier versions of these tow bars only - the swivel ears must be attached with the top facing up. To distinguish between the top and bottom, spread the tow bar arms about 28 inches apart. Place a swivel ear over a round nut and rotate it to the left or the right, to the approximate position it would be in when towing. When the top is facing up, the swivel ear will be at the same angle as
the tow bar arm.

9. Remove the shoulder bolt and, with the 1/4" Allen wrench and the 9/16" socket wrench, reattach the swivel ear to the round nut. Use the original shoulder bolt, the two original 3/4" diameter acetyl washers and the new Nylock nut.

10. Be certain to position the head of the shoulder bolt at the top of the tow bar - on the same side as the Freedom Latch. Before tightening the Nylock nut, make certain that the head of the shoulder bolt is flush to the swivel ear. Note: over-tightening the Nylock nut will bind the collar and prevent it from pivoting properly. When it is tightened correctly, the collar should pivot easily.

11. Check for correct installation - the swivel ear should rotate no more than 10 to 15 degrees in either direction.

12. Reinsert the end cap into the end of the tow bar outer arm.

13. The installation is complete. If a second inner arm is to be replaced, repeat steps 1 through 12.

expert reply by: Michael H

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