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  1. #1
    Seasoned Camper
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    DIY - Replacing Gas Strut on Solera Awning

    When my gas strut failed on my Solera awning the shop told me they had to replace the entire awning arm. The strut is less than $30, but be sure to order additional star lock washers, which is something the don't necessarily tell you.

    The biggest problem is getting the star lock washers off the strut pins. There are a number of youtube vids explaining how to do this, by prying open the locking teeth on the washer. This is no easy task because it is difficult to get the leverage.

    For me I had to extend the awning to its full length. This reduces the load on the gas strut to its minimum and exposes the star lock nuts.

    The easier way to remove the star nuts is to use a Dremel tool with a cutoff wheel. Carefully grind off about 3 of the lock washer teeth. At this point the lock washer should rotate independent of the strut pin. If it does not rotate freely, grind off another tooth until it does rotate freely.

    Once it rotates freely you can pry of the lock washer with very little effort and remove the faulty gas strut.

    The new gas strut is under a lot of pressure so it will be difficult to line up the strut with the pin holes. I THINK if you start with the bottom hole first I think installation will be easier. If you can compress the the strut up to an inch (but probably less) it will be easier to find a position on the awning arms that will allow you to mount the strut and pins.

    To install the new star lock washers can be seated with a pair of channel locks gently rocking the lock washer into place.

    Can you do this while on the road? I think so if you can find a Dremel and have the parts.
    Foard County News & Sassy Schoolmarm
    Nathan & Susan Gifford
    Belle, & Danke
    53 days camping 8000 miles 2017
    2017 Imagine 2800BH
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  2. #2
    Seasoned Camper
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    No need for a Dremel.

    Personally, I would rather replace the pins and washers with slightly longer threaded bolts and Nylock washers, but that is because I come from an automotive background and HATE those flimsy, easy-to-snap, cost-cutting washers.

    To remove one of those washers, take a slim-tipped screwdriver and pry one edge of the washer up far enough to get a large screwdriver tip under the lip.

    One good twist of the wrist and that puppy will either pop off or break in half and fall to the ground.



    If you just HAVE to replace them (and there are some applications where there is not the clearance for a Nylock nut), use an appropriately-sized nut driver to push the washer on, evenly.

    Just "pop" the end of the nut driver to get the washer started, then push it home.

    Be sure NOT to seat the washer tightly or your joint will not be able to move.


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  3. #3
    Site Sponsor Cate&Rob's Avatar
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    I replaced my Solera awning pivot pins with stainless steel bolts and nylock nuts . . . primarily because the star washers kept popping off. Bolted connections per attached pics have been working fine for several years.

    Rob
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  4. #4
    Site Team WhittleBurner's Avatar
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    I used to use a pair of side cutters for taking off star washers. Grab a-hold of one of the tabs and twist and pull.
    Marcy & Gary
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  5. #5
    Seasoned Camper
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    Quote Originally Posted by WhittleBurner View Post
    I used to use a pair of side cutters for taking off star washers. Grab a-hold of one of the tabs and twist and pull.
    Did not work for me. Too much arthritis in the hands and the pin and washer rotated too easily.

    I tried the pry method several times. I might have been able to that with a 3rd hand to secure the pin.

    On the other hand, a Dremel and 3 minutes and I could take the star nut off with my fingers.

    I like the stainless steel pin idea.

    Another nice thing about the dremel, is when you miss it cuts a really fine notch for the new starlock to lock into.

    The other idea of using cotter pins to replace starlock was suggested to me by others in SASS group. Some of them have had similar problems with their rigs and this was their permanent solution.

    The short story is, have an extra gas strut around. If you can compress it an inch before you install it and you can fix this fast on the road.

    Thanks everyone
    Foard County News & Sassy Schoolmarm
    Nathan & Susan Gifford
    Belle, & Danke
    53 days camping 8000 miles 2017
    2017 Imagine 2800BH
    '07 GMC Sierra 2500HD Duramax LBZ 4WD

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