23 - Stuck with 2000# Tow Capacity

After considerable research, I finally verified that this Orion tow hitch is rated for 2000 lb. There is no label or stamping on the hitch itself, but I confirmed the rating on a factory spec sheet. I went to a Yuma tow specialty and welding shop to see if it would be feasible to strengthen the existing hitch, or it could be replaced by a 3000 lb. hitch. The purpose of all this was because we would like to tow a slightly bigger car than the Smart. It would be nice to have the extra seats and room. I looked at a Ford Fiesta hatchback that weighs about 2700 lb., is flat towable, and we liked a lot.

The analysis was that replacing the hitch without strengthening the frame was not advisable. Beefing up the existing hitch would involve considerable modification and add weight to the coach. Plus, the shop really didn't want to try for liability reasons.

The pictures below show the issues. The first shows the hitch mount at the rear of the motorhome. The hitch end brackets are attached to the frame extension with only two bolts on each side (circled). I have to trust that Coachmen provided strong enough bolts for the rating, but four bolts are probably not sufficient for 3000 lb.

Even if the hitch was stronger, the frame extensions that Coachmen used are bolted to the Transit frame using eight bolts total. One side of the frame is shown below. This design may be sufficient to support both the weight of the rear part of the coach body and 2000 lb. of towing, but who knows what the reserve capability is? And that hitch connection is five feet back of the frame to extension joint, which means amplifying the sideways and vertical forces from the tow bar to the hitch.

So, I will take the safe route and stick with the current tow setup. That will limit our car options to a newer Smart at best, as any other towable car weighs at least 2300 lb.