Jayco RV Repair in Yorba Linda

The signature element is the arched aluminum roof truss with a one piece membrane over it. The arch gives the roof positive drainage and adds stiffness across the width of the unit, which is genuinely better engineering than a flat truss. Sidewalls on most current lines are vacuum bonded laminated panels, fiberglass skin over composite substrate over aluminum framing, with the interior panel bonded as part of the same sandwich.

On the motorized side, the chassis defines the collision work. Class C coaches use the Ford E Series cutaway, Super C units use the Ford F550, Class A gas coaches use the Ford F53, the diesel Embark uses the Freightliner XC, and the Class B and small Class C units use the Mercedes Sprinter cab chassis. A frontal impact on a Seneca is a heavy truck repair. The same impact on a Melbourne is a Sprinter unibody repair with ADAS calibration attached.

Towable frames are Lippert with Dexter running gear, the same as most of the industry, which keeps mechanical parts availability reasonable even on older units.

• Ford E Series cutaway on Redhawk and Greyhawk Class C
• Ford F550 chassis on Seneca Super C
• Ford F53 gas chassis on Alante and Precept Class A
• Freightliner XC diesel chassis on Embark
• Mercedes Sprinter cab chassis on Melbourne, Swift and Terrain
• Lippert frames and Dexter axles across the towable lines

All of them, motorized and towable, current and discontinued. Jay Flight is the highest volume travel trailer in the country and it is a large share of the towable work here. Greyhawk and Redhawk dominate the motorized side.

Starcraft badged units are built by Jayco and are covered here as well. They share framing, roof systems and slide mechanisms with the Jayco equivalents.

• Travel trailers: Jay Flight, Jay Feather, White Hawk, Jay Flight SLX
• Fifth wheels: Eagle, Pinnacle, North Point, Eagle HT
• Toy haulers: Seismic, Octane, Jay Flight Octane
• Class C: Redhawk, Greyhawk, Melbourne, Redhawk SE
• Super C: Seneca, Seneca Prestige
• Class A: Alante, Precept, Embark
• Camping trailers and pop ups: Jay Sport, Jay Series Sport
• Starcraft badged equivalents: Autumn Ridge, Super Lite, Telluride

The front cap radius seam is the most common Jayco failure and it is a direct consequence of the arched roof. Where the arch meets the moulded cap there is a compound curve, and a compound curve is the hardest joint in the industry to seal reliably. It moves in two planes with every temperature cycle. Owners see it as a stain in the front overhead cabinet or a soft spot in the front ceiling long before they see anything outside.

Slide rail wear on Eagle and Jay Flight units follows the same pattern as the rest of the industry, because the mechanism is Lippert and the failure is out of sync operation wearing one rail faster than the other. On Eagle fifth wheels the additional factor is that the living room slide is heavy and long, which accelerates it.

Lower sidewall delamination on Jay Flight is common on units that have spent years parked without a cover. The lower few feet of sidewall take the most road spray and the most standing water, and once the bond fails at the bottom edge it climbs. On Seneca Super C units the recurring issue is the cab to house seam, where a Ford F550 cab and a Jayco house move independently and the seal between them takes all of that motion.

• Front cap to arched roof compound radius seam leakage
• Stain or soft spot in the front overhead and front ceiling
• In wall slide rail wear on Eagle and Jay Flight rooms
• Lower sidewall delamination climbing from the bottom edge on Jay Flight
• Cab to house seam separation on Seneca Super C units
• Cabover seam leakage on Redhawk and Greyhawk Class C coaches
• Roof membrane termination failure at the rear cap

Jayco parts support on current production is reasonable and the fact that Jayco sits inside the Thor group means some components are shared across brands, which helps. Moulded caps for discontinued lines are the usual problem and are frequently unavailable, particularly on older Class C units where the cap and the cabover are a single part.

We mould fiberglass cap and cabover sections in house from the surviving side or a donor pattern. Roof truss members and framing are fabricated here to match original section. Slide, frame and axle components are Lippert and Dexter and remain broadly available.

On cost, motorized collision runs $1,000 to $150,000 and up at 5 to 800 or more hours. Camper and fifth wheel collision runs $750 to $50,000 and up. Water damage and delamination runs $750 to $18,000 and up at 5 to 80 hours. Fiberglass cap repair runs $750 to $12,000 and up at 4 to 60 hours. All at $210 per hour body and paint, $260 per hour mechanical and electrical.