How to Repair a PopUp Camper Cable

Popup campers rely on pulleys, a crank, and four cables to make the popup portion of the camper operate; if a cable breaks or fails, the camper will not operate correctly. Occasionally, the cable to a popup camper will suddenly break and if the camper owner does not know how to repair it immediately, it can ruin vacation plans. Repairing a popup camper cable can be accomplished in about an hour.

Things You'll Need

• Aerosol lubricant
• Anti-seize lubricant
• Cable repair kit with pulleys and brackets
• Marker pen
• Measuring tape
• Saw
• 4 -- 2x4s
• 4 -- C-clamps
• 4 -- Scissor jacks
• 4 -- Vice grips
• Wrench

Instructions

The Process

1. Raise the popup camper roof slowly, using one scissor jack on each corner. Once the roof is raised as far as the scissor jacks will allow, clamp the guide rods with the c-clamps and vice grips.

2. Use the measuring tape to measure the distance from the ground to the lowest part of the camper's popup roof. Measure and mark a 2x4 to the length obtained during the roof-to-ground measurement. Cut the 2x4 to the determined length with the saw. Repeat this process three more times with the remaining 2x4s.

3. Vertically position one 2x4 under each corner of the popup camper.

4. Apply the anti-seize lubricant to the four cranks located beneath the popup camper corners to make the parts move with ease.

5. Apply the aerosol lubricant to the all the cables and pulleys, and to the corner cables underneath the four corners of the popup camper. Locate the cable that requires repair; see if the cable has slipped off the pulley tracks. Reposition the cable back onto the pulley if necessary.

6. Use the wrench to remove the pulley if it requires replacement and put on the new pulley. Replace the bolt and tighten it. Remove the two fittings attaching the main assembly tube. Attach the new popup camper cable to the distribution box using the brackets included in the repair kit.

7. Replace the fittings in the main assembly tube. Align the cable in the pulley track and attach the opposite end of the cable to the winch.

Tips & Warnings

• Be careful that you do not bump into the 2x4 supports since it can jar the popup roof and cause it to fall.

Resources

• Read this Article in Spanish
• Custom Cylinders International Incorporated: An in-depth article with diagrams of the popup camper lift system.