Finding Replacement Suspension Bushing for Entegra/Jayco Arc Promaster

[PreciousRoy]

Hi all,

I was working in the garage yesterday and noticed that I have a leaf spring hanging free under my van. It's an Entegra Arc (same as Jayco Comet) which is based on a Promaster 136" window van.

Looks like the bushing that was supposed to be between the helper spring and the factory leaf pack has gone on leave. I'm looking to see if I can find a part number or spec to order a replacement, but my online searches haven't been fruitful.

The van is advertised as coming with Helwig helper springs, but the bushings that are left on the van don't look at all like the ones that come with the Helwig spring kit. I'm guessing that is because when Jayco built the van they also raised the suspension, requiring a taller helper spring bushing.

I'd like to avoid using an RV dealership if possible, first because I'd rather not deal with scheduling the appointment, driving 2 hours to the dealer, waiting, enduring the inevitable upsell to synthetic blinker fluid, etc. Second, I don't think I should really be driving much at all with a mismatched spring rate on either end of the axle.

(I realize that this is very likely a covered warranty repair, but the dealer is La Mesa, so...)

Here's what the other side looks like:

The bushing is approximately 3.075" tall and 2.75" in diameter.

Does anyone know how I might be able to find the exact replacement part or at least a compatible generic one? I've tried searching with terms like 'helper spring bushing', 'leaf spring bushing', 'helper spring spacer', etc., but haven't found much of value other than ads for entire helper spring kits.

 

[booster]

Have you contacted Hellwig or looked at their site?

That doesn't look like anything the Helwig would want related to their products as it very backwoods of a fix.

It almost looks like they put the helper on the wrong side of the axle because it was easier.

 

[PreciousRoy]

Yep. The tech support guy I contacted didn't want anything to do with it. The spring does install below the axle like that, but Jayco apparently lengthened the bushings (or just lengthened the bolt and added a spacer. Either way, it seems the additional lateral load either sheared the bolt, or they just failed to torque it properly.

He also mentioned that they voided the warranty in the process. (hooray!)

I'm going to contact Jayco parts and see if I can get anything there, but I may just be searching for a new bushing. You'd think it'd be easy to find what essentially amounts to a polyurethane puck with a threaded insert, but I'm not having much luck so far. It doesn't help that most products with 'leaf spring bushing' in the name are for the actual shackle on the vehicle, not to slip between two springs.

 

[youngnretired]

When I zoomed into your picture it looks like maybe there's two bushings stacked on top of the other. Could there be two rubber bushings in there with a longer bolt?

I googled "3" tall and 2.75" diameter suspension bump stock" and found results that could possibly be a fix for you, or at least some different company names to dig into further. I tried bump stock only because you weren't finding anything by searching for bushing and to me it looks like a bump stock. If you do find that there are two rubber pieces in there, that may be an easier piece to find than the one tall piece. Also could be that if it is two pieces, its weaker than a single taller piece or vice versa.

 

[booster]

Go back to the first pic and look at the area above the axle. There appears to be something of different material or origin there as it looks rusty when nothing else does.

If that is a height spacer for the axle, it would explain it all because without it the booster spring would be right on the main spring or very close to it.

I looked at every part that Hellwig makes and nothing looks like that spacer and they don't list a helper springs for a Promaster.

If that spacer does have a big bolt through it, that is odd also because you normally don't want to be drilling extra holes in leaf springs and especially if you bolt the two leafs together as they need to slide on each other.

I would just get rid of the helper or put it on top of the axle and see if it fits. If that doesn't work, take it to a spring shop and have them put an extra leaf or air bags on it.

 

[youngnretired]

After re-reading my post, I went back and looked, and yep, I searched for "stock" and meant to search for "stop". However, this time google was smarter than me and gave me results for bump stops......

I did a little more looking this morning and find these: Competition-Style Bump Stops - Single Stud Plate - 3" Tall (Pair) These aren't round, but the rectangular shape may actually help resist tearing the rubber as the helper spring slides on the spring pack above. Only question is the diameter of the hole in the spring and stud size on these.

I also found 5" tall wedge shaped bump stops that were solid rubber and similar in appearance to the one's above.

Also found a company called "torklift" who does suspension upgrades and has bump stops, but I can't find their bump stops on their website.

Also, just curious, are these bumpers on one end of the helper spring or on both ends?

 

[booster]

I think this is the only Promaster with booster springs, as most everybody else uses Sumos to do the job.

 

[PreciousRoy]

Yeah, I'm surprised they didn't use Sumosprings, actually. The Hellwig kit for Promaster is EZ-990 FWIW.

The rusty block in there is the 1.5" lift block that Jayco/Entegra installed to increase ground clearance for the genny & tanks. I believe what they did with the bushings was replace the original bushing bolt with a longer one, then stuffed a 1.5" spacer in between to account for the extra distance. That would retain the spring rate in theory.

The problem with what they did is in addition to the vertical load between the factory leaf and the helper leaf, there is also lateral force as the bushing slides fore and aft as the springs flex. Increasing the height of the bushing increased the shear force on that bolt and, well, there we have it. I'm sure that bushing is lying along one of the twisty, bumpy coast highways. I've only taken 2 trips in this van since it was purchased.

Thanks for finding that bushing, youngnretired. Those might get me back on the road while I decide what to do here. Entegra wants me to take it back to the dealership before they'll have anything to do with it, so I may just forego that and consider this an opportunity to upgrade the suspension. I really liked the air helper/leveling kit I had on a Chevy pickup many years ago. Might do something like that in the long term.

 

[booster]

I am also a big fan of the airbag helpers in the rear, and it would allow you to get rid of the non stock stuff except maybe the blocks, depending on road clearance. We have had bags in our Chevy 190 for over 15 years.

I see that Airlift does now have both 5000# kits for Promaster, the normal bag one and the the one with the urethane internal bump stop.

Forget what I said about adding a leaf, as I didn't realize bags were now available. Bags are far and away the best solution IMO.

 

[PreciousRoy]

Yep - I had a Firestone system with an on-board compressor long ago on my Chevy pickup and it was great.

Now that I've found the universal bump stops, it looks like I'm in at least $250 for a set of 4 that are tall enough to keep the Hellwig springs in their normal tension range and even then the lateral load from the leaves sliding against each other will likely shred them in short order.

For a little under $100 more, I could swap them out for Sumo springs. However, for a little bit more than that, I can get the Airlift springs. Honestly, since Entegra stacked all the appliances and the fresh tank basically on top of of the right rear wheel, going without onboard air would allow me to run the right side a little stiffer to compensate. Seems like a no-brainer to me.

I believe I'll drop the Hellwigs and install Airlift bags instead. Maybe some day I'll replace the small bushings from the Hellwigs and sell them to another Promaster owner that isn't running lifted suspension.

The way they cobbled those bump stops together seems like such a mickey-mouse hack for a new big-brand RV, but I guess I'm not all that surprised.

Thanks for all the info!

 

[booster]

Sounds like a good plan to me.