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Replace the hardware on your Roadmaster Falcon All-Terrain or BlackHawk 2 All-Terrain tow bar.
Features:
Videos are provided as a guide only. Refer to manufacturer installation instructions and specs for complete information.
Hey everyone, Shane here with etrailer.com. Today, I have a Roadmaster Falcon All-Terrain Tow Bar. I'm going to walk through how to install the Roadmaster tow bar repair kit. The reason why you'd want a repair kit is if we have an older tow bar. Maybe the arms are starting to corrode a little bit. They're a little bit hard to slide in and out, maybe they get stuck.
The repair kit's going to come with all new bushings for not only this end, but everything in between here, and also up here on the end that connects to the vehicle. It's going to give you everything you need to get new bushings put on so everything moves nice and fluent just like you had when you bought it new. The kit is going to come with a new nut here, a new nut for here, all of your nylon bushings, not only for the specs, as I mentioned earlier, but also everything in between here and then at the end here where the end of our brackets are the tie into our vehicle.It's going to come with nylon bushings as well as a new bolt and new nut for these ends. Now that we've gone over some of the features, let's walk with you out to get it installed. Before we start our installation on replacing the internal components on this and cleaning it up, I want to show you why we want to do this.
If you notice this bar's pretty roughed up. The inside of this square tube here, it has a little bracket that slides in and out of there, and if it gets gunked up, that makes it real hard to get that bar in and out. You can see this one is kind of a pain to get it to move. What we want to do is, we're going to replace the bushings on the front here. We're going to replace all the bushings on the backside here, so that it will free it up and move a little bit easier.To start, what we're going to do is, this end here, and take note of how it is attached on there, we're going to take this end off.
If you notice this is the top of our tow bar. Notice how that's facing in. We're just going to spin that as much as we can here. We're going to take a 1/4" Allen wrench for one side and we'll use a 9/16" for the nut. Remove that.
Your kit's going to come with new bolts, so we won't need these. We're also going to be replacing the two bushings, so we won't need those. What we're going to do is we're going to take this and we're going to mark where it is on the bar, and then we're going to unscrew it because this rod has to slide out the other end. Let's take a marker, just like that. We'll just thread this off. You can kind of see all the gunk that's coming out of there. We're going to get all that stuff cleaned up.This bolt that runs in between the two arms is going to have to come off. These plates aren't on there correctly. I'll show you how to put them on correctly once we get this arm cleaned out. To get this off, you're going to need a 5/8" Allen head, and you're going to need an 1 1/8" socket for the nuts side. We're going to take this one off first, and then we're going to remove this one. You're going to want to hold on to these and these, because these and these two washers are going to go back on. On the backside, you're going to have a plastic cap. We're going to pry that cap off, and we're going to slide our bar out at the end. You're going to get replacement caps, so if you mess this up, don't worry about it, we're going to be putting new ones on.We'll just take a flat head screwdriver, kind of feed it in along the edge, and pry that cap out all. We're going to slide our bar out of the end. You can see how dirty that is. This is what I was talking about. That slides inside of the square tube. You can see how gunked up it is. That's what keeps it from sliding in there. We need to get all that cleaned out as well as the inside of the square tube itself.We're going to start by cleaning off our rod. It really doesn't matter, you can start with either one, but you want to make sure you use a water-soluble cleaner. Voom RV cleaner works great for getting some of that gunk off. We're going to take it, and we're just going to spray it on there. This stuff kind of smells like a Windex almost. It really doesn't have a hard, strong smell to it. I'm going to let that soak in for a minute before I wipe it off. I'm going to take my square tube, and spray it down inside and get that all over inside of there.Let that soak in for just a second. Then what we're going to do is we're going to take a paper towel, and we're going to wipe them off. We'll take a paper towel and we'll shove it down inside, and we're going to try and get as much of that stuff out of there as we can, until we think it's clean enough. We're going to rinse it out with water, dry it. Make sure it's dry before we put all of our components back together. You can see what a difference it made on that bar, getting all that stuff off of there.What I'm going to do is, I'm taking a single paper towel, and I'm going right here in the small end. Get that shoved in there. We're going to follow it by another one. It's really up to you, how you do this part of it. That's just how I found works. Then you can take a couple of long extensions like this, take the back end, and we're going to push it out of the bottom side. Can you see how much gunk and stuff is in there Just repeat that process until you get it clean. We're going to take it over to a hose. We're going to make sure we rinse all the solvent out of the inside and off of the arm. Then we want to make sure it's completely dry before we put it back together. It's basically dried out. We've run our towels through there again, dried off our bar.We're going to let it sit and completely dry. While we do that, we're going to go ahead and take this bolt off. It's going to make it a lot easier when we go to put these arms back together if this is off of the tube. We're going to start putting our arm back together. Your kit's going to come with a bushing. It's going to look like this. Depending on if you have an older or newer Falcon All-Terrain Tow Bar, there's a bushing right here on the end. This is going to be for an older one. If it looks like this, it is not going to be replaced. We're going to leave that in, and then we won't be using these. We're going to take our bar and insert it into the square tube.We want to make sure the square side is facing up towards the top. Wherever your release lever is, you want that facing up towards that. Slide it in like this. You may have to pick up your tow bar, so that slides through. Come to the end. We'll go ahead and thread the end piece back on there until we hit our mark. You can see that our. What we want, if you look inside of there, the end of our bar has got a moon shape in it. We want that to be lined up with the hole in the side of this end bracket here. We're going to put our bracket on the end. You remember, as I mentioned when we we're taken off, take note of how it was sitting. This is a way it's going to be put on, angle facing in. This is our outside. This is our inside. It's going to come with a new bolt. We're going to start by taking our bolt, we're going to slide it in like this. One of our new bushings, we'll slide it on, and get our bolt down through the hole.Nylon lock nut on the other side. We want to make sure when we tighten this down, we're not over tightening it to where it's squeezing it to where this can not rotate. We just want to tight enough to where there's not a whole bunch of play in it. Once you get one arm done, you're going to repeat the process for the other arm. We'll take our two arms, we're going to take this bracket here, we're going to take one of our bolts, and we're going to put on the metal washer. As I mentioned, hold onto it. We're going to feed it through like this.Notice I'm using the one that has the sticker on the top. It's going to be my top one. If your sticker has worn out, you'll notice that this plate here, the shape of it, this is going to be your top bar or top plate, I should say. Slide it in like that. We're going to put on a nylon washer. We're going to take this plate, slide it on, put another nylon washer on. We're going to take our other arm, and you may want to have two people to help you do this. Once you get your bolt in and this bracket in, you need to get another nylon bushing right down inside of here.Once we get that bushing in, you may take a pair of vice grips and kind of squeeze these together, cause this one here is a little bit hard to get in. Get this plate in here like that, and it's going to fit in the grooves on that. Let's slide our next bushing down on in place like that. Then we'll get one more bushing on this outside. On the bottom, put our metal washer, and then the new nut. I'm going to tighten them down tight, but we don't want it so tight that this does not move. Once you get all that tightened down, go ahead and move everything. Kind of move it around, make sure there's not too much tension on it. If there is tension, you want to loosen up the nut a little bit, cause we don't want to wear out the bushings that we just put in.We'll move this around. You see we got plenty of movement with that. Move our arms. Make sure that these are not real tight again. We're good. Once you've made any adjustments necessary, you're ready to go. That's going to do it for a look at an installation on the Roadmaster repair kit for Falcon and Nighthawk All-Terrain Tow Bars.
Average Customer Rating: 4.7 out of 5 stars (66 Customer Reviews)
Replace the hardware on your Roadmaster Falcon All-Terrain or BlackHawk 2 All-Terrain tow bar.
I have had my Roadmaster tow bar for 16 years. It needed to be rebuilt I found the rebuild kit at etrailer, ordered it. Was exactly what I needed
It took way to long to get it here. Sorry but was not up to the service you normally provide.
The kit is very complete. The bushings worked out great. I ran into an issue with the bolts. When I started to tightn the nut on one of them it siezed up on the bolt. I got ill and have not dealt with it yet. Probably a good suggestion would be to apply some anti sieze to the threads before the nut. I will either have to apply moderate heat or even cut the nut.
Thanks again etraier for the quick ship. The videos you provide for install are a tremendous help-
The product was great quality and how to replace bideo very helpful. However, the two 3/4” lock nuts on my towbar were very difficult to remove, requiring heat and a ton of effort. Not as easy as the video shows.
The Road Master Falcon 2 repair kit arrived much sooner than expected. However, the instructional photos are not well displayed (darker and less contrast) clarity. Overall I highly recommend etrailer’s custom service and product.
I haven't done the repair yet, but I have used your repair kit before and it was great. I'll let you know if I have a problem. Thank you. Tony
Tony
11/25/2022
I installed it its been a year and the product is working fine. Will reorder when I need another rebuild
I bought a service kit for my Roadmaster falcon after hearing reports that it would make my tow hitch like new. Unfortunately the bushings seem to be too thick so the arms cannot extend without serious pulling. I called tech support and they suggested using very fine sandpaper. Four hours later and still the same problem. What should have been an easy job has now turned into a real headache. I cannot tow my car at all now and my wife is left to drive the car while I drive the home.
Mike L.
7/11/2019
Over the years, Roadmaster has manufactured three different Falcon towbars. The original 5250, the Falcon 2 and the Falcon All Terrain. The correct repair kit will depend on exactly which towbar you actually have. Original 5250 would use # RM910003-52 The Falcon 2 would use # RM910003-65 The Falcon All-Terrain would use the kit you purcahsed, # RM910003-85
Helpful Links
Accessories-and-Parts/Roadmaster/RM910003-52.html
I rebuilt my Falcon tow bar using the kit from etrailer. Their video online was step by step easy to follow and everything turned perfect. It’s been close to a year now and several thousand miles of towing my mid size SUV and no issues.
My towbar arms absolutely refused to extend or retract, even after pounding them with a 6 lb. maul. The people at Roadmaster recommended this kit. The repair kit was very well put together, but what really impressed me was the knowledge of the gentleman at etrailer who helped me on the phone and gave me pointers on things to do to make the repairs work. I followed his lead, and the tow bar worked amazingly well and continues to work well one year later. Because of this service, I have become a faithful etrailer customer.
All parts necessary to perform repair on my hitch.
I ordered the rebuild kit for my Roadmaster towbar along with new bushings from Kaylyn on 3/12 and received the parts on 3/18. That’s really fast service, and Kaylyn was very sharp about what I needed and only what I needed. Rebuilt the towbar yesterday and now it’s like new and I can collapse it like it was designed to do, previously I could not telescope the drivers side arm so it was difficult to hook up and unhook car. Couldn’t be happier with the price, delivery and professional advice I got with this order. You rock Kaylyn, oh and you too etrailer.
I had to recently replace a bent arm on my Falcon All-Terrain towbar. Since it was going to be apart I knew it would be a good chance to clean and inspect the complete towbar and replace the wearing parts. While nothing was in horrible shape, it now is "like new". I am thankful parts are still available for a towbar that has served well since 2006!
Excellent kit, just what I needed.
As always, etrailer came through.
Before rebuilding the tow bar my toad was all over the place, especially on uneven surfaces thru construction projects. Now it tows straight as an arrow. Well worth the time and money. TIP: Don’t lose any of the handle parts on the tow bar, you can only buy an entire kit not just the pin I needed.
Great service. Appreciate the fast response to our problem. Thank you Noah.
I received a complete rebuild kit for my Falcon All-Terrain tow bar, which was at a fair price with quick delivery. etrailer appears to be the only one handling this product, which is a vital part for flat towing my jeep
I've ordered many items from etrailer and made many phone calls due to my inexperience trying to set up a TOAD. Every time I looked you had the part and each phone call connected me to a very helpful and knowledgable person. Thanks for the help. Hope to see you guys on the road sometime.
The tow bar repair kit arrived in two days. The instructions was very complete and the installation was not difficult, now the tow bar is like new.
I'm very satisfied.
Every one I dealt with was very helpful in filling my order to my satisfaction.
Thanks for your help..........
Great product. Should be updated to include new bushings RM-200029-70.
Arrived quickly and well packaged.
Rachael H.
6/26/2018
I confirmed with my technical contacts at Roadmaster and depending on the serial number on the towbar may need other parts, but according to her records no additional bushings should be needed for the Blackhawk towbar.
As advertised. Complete and good quality. Nice to have multiple etrailer install videos for reference. Good product. Good company.
The instructions given were not very helpful. The video was very helpful. The tow bar should have been built with stainless steel. It was full of rust but nowhere was that talked about. They just addressed dirt on inside tubes.
Exactly what was needed to rebuilt my Falcon towbar. Fast delivery too!
Haven’t installed yet, but look to be exactly what I need to rebuild my tow bar.
I have not gotten my parts yet put my toe bar back together with out them
Jenny N.
11/5/2022
Oh no! I will have our customer service department assist in tracking the order.
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Brian A.
4/13/2023
After a little heat I was able to get the nut off without damaging the bolt. I used the old nut with red loctite and a jam nut for insurance. It appears the nut was over crimped at the lock area. That is what caused the issue.