Awning Fabric and Motor Repair for THOR CHATEAU
This comprehensive guide will walk you through repairing awning fabric and motor repair on your THOR CHATEAU. Follow each step carefully and gather all required parts before beginning.
Required Parts
- Replacement awning fabric (measure existing awning) – Part Numbers vary by length: typical sizes 8′, 10′, 12′, 14′, 16′, 18′, 20′, Brand: Carefree, Dometic A&E, Solera, Price Range: $200-$600 depending on length
- Awning motor replacement (for power awnings) – Part Number: Solera 291579 or Carefree 901040, Price Range: $150-$280
- Awning roller tube – Part Number: Varies by awning brand and length, Price Range: $80-$180
- Awning fabric pull strap – Part Number: Universal replacement, Price Range: $15-$25
- Awning de-flappers/wind stabilizers – Part Number: Universal fit, Price Range: $20-$35
- Awning rail lubricant – Part Number: 3-in-1 silicone spray or similar
- Safety strap or rope (for securing awning during work)
- Ladder tall enough to reach awning roller
- Assistant (strongly recommended – awning work requires two people)
Step-by-Step Instructions
Step 1: Awning System Assessment and Safety
The Thor Chateau typically features a main patio awning over the entry door area, ranging from 14′ to 21′ in length depending on the RV model, plus potentially additional window awnings. These are usually Carefree, Dometic, or Solera brand awnings, with newer models featuring electric operation. Before attempting any awning repair, start by determine whether the issue is the fabric (tears, severe fading, or mildew), the awning roller mechanism (bent roller tube, broken arms), or the motor (for electric awnings). Inspect the awning fabric by partially extending it and looking for tears, excessive wear along the hem, UV damage (fabric that’s become stiff and brittle), or mildew staining that won’t wash out. Check the roller tube for bends or dents by observing whether the awning rolls up evenly or has waves and wrinkles when extended. For electric awnings, test the motor by activating the switch – you should hear the motor running even if the awning doesn’t move.
Step 2: Workspace Setup and Safety Measures
Awning repair is one of the more hazardous DIY RV projects due to the height involved, the tension stored in the awning springs, and the length of the components you’ll be handling. This is not a solo job – you absolutely need at least one assistant, preferably two for larger awnings over 16 feet. Park your RV on level ground in an area with adequate clearance on both sides and overhead (avoid trees or power lines). If the awning is already deployed, secure it in the extended position with tie-downs or support poles before beginning work – this prevents the awning from accidentally rolling up while you’re working on it. Set up two sturdy ladders, one at each end of the awning, ensuring they’re on solid footing. Never work on an awning in windy conditions, even light breezes can cause dangerous movement. Have a helper on the ground at all times to stabilize ladders and assist with the long, awkward components.
Step 3: Awning Fabric Removal
To remove the old awning fabric, start by fully extend the awning and secure it to prevent movement. Most RV awnings attach the fabric to the roller tube via a rope-in-rail system – the fabric has a cord sewn into each edge that slides into channels on the roller tube and awning rail (mounted to the RV sidewall). Starting with the awning rail (the channel mounted to the RV side), you’ll need to slide the fabric out from one end. There’s usually a cap at one or both ends of the rail that can be removed by prying gently with a flat screwdriver. Once the end cap is off, you can slide the fabric cord out of the channel. This requires patience as the cord may have swollen over time or accumulated dirt – work it gently from the uncapped end toward the opposite end. Once free from the awning rail, the fabric can be removed from the roller tube using the same sliding technique.
Step 4: New Fabric Installation
Installing new awning fabric is essentially the reverse of removal but requires careful attention to ensure the fabric is oriented correctly and installed without twists. Most awning fabric has a definite “top” and “bottom” as indicated by the hem stitching pattern or manufacturer markings. With the awning arms fully extended and supported, begin by sliding the fabric cord into the roller tube channel from one end, working slowly to ensure the cord seats properly in the channel groove. This is where having a helper is essential – one person feeds the cord into the channel while another pulls the fabric taut to prevent bunching. Once the fabric is fully installed in the roller tube channel, carefully roll the awning up partially (by hand, not with the motor) to provide tension, then slide the opposite fabric edge into the awning rail mounted to the RV side. Again, work from one end to the other, ensuring the fabric remains straight without twists. Install end caps on both the roller tube and awning rail channels.
Step 5: Electric Awning Motor Replacement
If your Thor Chateau has an electric awning and the motor has failed (indicated by the motor humming but not turning, or complete silence when activated), motor replacement is necessary. The motor is typically located inside one end of the roller tube. First, fully extend and support the awning to release spring tension. Disconnect the power wire to the motor (usually a simple plug connection at the end cap of the roller tube). Remove the end cap of the roller tube by unscrewing 2-4 screws. The motor is usually held in place by a retaining bolt or clip that passes through the motor shaft. Remove this fastener and gently slide the motor out of the roller tube. Take note of any shims or spacers and their positions. Install the new motor by sliding it into the roller tube, ensuring the motor gear engages with the roller tube’s internal ring gear properly. Reinstall the retaining hardware and reconnect the power wire. Test motor operation before reinstalling the end cap.
Step 6: Awning Arm Adjustment and Alignment
Proper awning arm adjustment is critical for even fabric roll-up and preventing premature fabric wear. The awning arms contain strong spring tension that powers the automatic roll-up function – be extremely cautious when adjusting as sudden release of spring tension can cause serious injury. Most awning arms have a tension adjustment mechanism at the roller tube end, typically accessed by removing a cover or cap. The tension is usually adjustable by rotating a hex bolt or square shaft. Equal tension on both arms is essential for even roll-up. To check alignment, extend the awning fully and observe whether the roller tube is parallel to the RV side or if one arm is extended further than the other. Adjust arm length to achieve perfect parallel alignment. Also verify that the awning pitch (angle) is sufficient to shed water but not so steep that it causes stress on the fabric or arms.
Step 7: Final Assembly and Testing
With the fabric installed, motor replaced (if applicable), and arms properly adjusted, perform a complete function test of your awning system. For manual awnings, use the pull strap to slowly roll up the awning, watching carefully to ensure the fabric rolls up evenly across the entire width without bunching on one end or developing wrinkles and waves. The fabric should roll tightly and evenly. For electric awnings, use short bursts of the switch to control the motor while observing fabric roll-up – don’t just hold the button and let it roll up unattended. Once fully retracted, install the travel locks (straps or clips that secure the awning for highway travel). Extend and retract the awning 2-3 times to verify consistent, smooth operation. Apply silicone lubricant to the awning rail and all moving pivot points on the arms. Educate all RV users on proper awning operation: never leave extended in wind, always retract when leaving the RV unattended, and never roll up a wet awning for extended storage (it will mildew).