Workhorse Chassis W24 W22: How to Remove & Replace Fuel Tank & Fuel Pump By Your Self and Save.
Vložit
- čas přidán 27. 08. 2022
- Workhorse Chassis W24 W22: How to Remove & Replace Fuel Tank & Fuel Pump By Your Self and save money.
Also learn how to extend the Onan fuel pickup tube for longer run time.
Parts and tools I used
New OEM Fuel Pump NOT after market
www.ultrarvproducts.com/W0013...
Part# W0013952
Description:
Brand New Workhorse In Tank Fuel Pump for 2004+ P32, W16, W18, W20, W22, W24, W42
Replaces 25353893 25371178 28056423 28105800 25380389 25348548 25322995
Lisle 37000 Air Conditioning/Fuel Line Disconnect Tool Set
amzn.to/3wB4O55
304 Stainless Steel Single Ear Hose Clamps,6-28.6mm Stepless Hose Clamps with Ear Clamp Pincer,Cinch Rings Crimp Hose Clamps Assortment Kit for Water Pipe, Plumbing and Automotive Use amzn.to/3pTa6VY
My fuel pump comparison video to OEM vs after market
• Your Workhorse Chassis...
My Trap door video for 38J owners
• For Winnebago 38J Owne...
You make it look easy. Wow. You must live in a rust free zone!
Kevin, Always Appreciate your genius mind and Ideas... and your extreme patience, making a big job way easier for us diy peeps!! You're the Man !! Have a great one. And thank you much for sharing and for your time making your videos !!
Scott
More to come!!!
Excellent video! You made a daunting task almost enjoyable! I had to do a tank drop on my 83 Winnebago 33' in 2019 and I used 2 floor jacks, a great neighbor and a lot of prayer. I'd still pray with your improved system, I like/need Heaven's help. God bless you brother.
Good job Buddy!!
I actually dropped mine this way in a motor home park on gravel. I just spread my patio rug under there and that way this ole blind man didn’t lose any parts or tools.
I will definitely cut the hole in the compartment above if there is ever a next time!!
Thanks for the very detailed video
Thanks Kevin for the great video, all of them. We own a 2007 Adventurer on a W-24 chassis and on our current trip experienced a gas smell in the rear bedroom, not good. So in Lubbock TX, we had a shop lower the tank and replace the fuel pump. I had it shipped in from Ultra RV, but didn't have a shop or jacks to do the job myself. Two days of driving post repair, everything is fine, today we are losing power while towing Buick Envision. Unhooked the car and shut everything down to do a visual under the rig. No leaks or smell. But engine doesn't want to start like it did. I am wishing I would have had the shop put on a new fuel filter....they may have some dirt that got into the tank. The other reason I think this is the Onan generator ran briefly, but then shutdown. It has been several years since I replaced that fuel filter, so am off to the auto parts store tomorrow. Hope that fixes the problem.
Call me I have some questions 606-875-0125 Kevin
So what did you find??
Replaced fuel filter yesterday morning, traveled 120 miles towing just fine, then lost power again. Limped into town, unhooked car, changed filter again, added two bottles of Techron,drove 220 miles with spouse following in car, motorhome ran like a top.
@@GarySieverding Good to hear.. do you own a scan gauge 3 ? every 8.1 owner should have one running your engine lean can be very costly. check out this video
czcams.com/play/PL2iVqSqj_ofsDtD6EVvlyunUHaugywPjj.html
I bought my Newmar with 8.1 because you
And I'm very thankful for your videos
Thank you!!!!!!!!!
Thank you for the kind word Andre are you in the US or another country?
All thread tip is genius.
Kevin - You have helped "Save the day" with our RV and required fall--> winter travel.
As mentioned in your fuel pressure gauge video our 2005 Winnebago Adventurer 37B (W22 chassis, 80,000+ miles) began running poorly - low power, backfiring, low power on hills, ck engine light coming on a lot. So I installed a fuel pressure gauge, as you suggested, only to see that we were running at 40 psi. Not good - as it indicated that our pump could have failed at any time. I was reluctant to replace the pump due to the cost, and due to the outside driveway we were staying at in upstate NY with winter old coming on strong. But not sure we could make it south so I followed much of your video to make the repair. So glad I did. Thank You!
Some of my thoughts -
* I used 3/8" threaded rod because my local Tractor Supply was out of 1/2". But with some washers under the nuts they worked just fine. This method proved to work quite well as the tank could be easily controlled for optimum height - necessary for gaining better access to side filler tubes.
* Cleanliness, cleanliness, cleanliness! As you mentioned many times a lot of dirt can accumulate on top of the tank. So when I lowered the tank and had access to top of fuel pump I used a shop vac to totally clean up much of the dirt here - especially in the top of the old pump.
* Disconnecting the old pump fuel pines. With the fuel line removal tool set I got the RH line was very easy to remove, but the center one was just impossible. I would love to talk with the OE design engineer on why they provided virtually no room to insert the tool on it. I tried your great idea of cutting a bit of plastic tube and trying to force that up under the locking teeth - but could not find one that worked. Eventually I simply cut off the entire nipple with a dremel tool as it was the only way to get the line off. So had to totally destroy the old pump. (Not that I would have wanted to re-use it though)
* 1st hard part - I had some very rusted nuts on the tank hanger bolts. Even though I sprayed all with lots of penetrating oil and used a threaded die to clean up the lower, exposed threads, some were rusted so much that my wrench could not loosen them. So I resorted to a long breaker bar, with extension, which literally snapped some of the hanger bolts off. But I found that replacement bolts with washers worked just fine to replace those. (I think I found that 1/2" x 2 1/2" Grade 5 bolts worked fine. Just had to be sure to install them in the upper hanger before bringing the tank back up.
* As per prior comment - when I re-assembled all the hangers I made sure to totally clean up the threads on all remaining good hanger bolts ( and nuts too), and thoroughly coat all nuts & bolts with grease - to help ensure they would not seize up again. I have found this be fairly necessary on most chassis bolts to help keep water out of the threads and to prevent corrosion between the nut & bolt from happening again.
* I wanted to extend the gen PU tube, but mine was very stiff - stuck in place. So rather than risk damaging it just left it alone.
* Most difficult part of this project was dis-connecting and re-connecting the side filler tubes. VERY hard to reach and manipulate. Found the harder ones were actually the short blanking tubes on the non-fill side. In both removal and re-install found I had to carefully control tank height in order to gain best access. In other words - had to partially lower tank. Wish much larger cutouts were made in the frame rails.
* Fuel pump. I searched high & low for another source of the OE fuel pump. Agree that only an OE should be used, but the price charged by Ultra RV was ridiculous. Especially when there are so many other very similar types of pumps (Delphi and after-market) available for hundreds less.
This fuel pump replacement project was the most difficult repair I have ever had to do. All that crawling around the tank really got to me. Got really sore and it made for very slow going. But thanks to this video I was eventually able to complete it successfully. My fuel psi is now back up to in range, and the engine runs great again. So it was something I had to do in order to keep driving it, but sure wish they had made the fuel pump more accessible. In my model (37B) there was no option to cut an access panel in the floor above the tank as there is a water tank there.
Thanks again Kevin for creating this video - it helped so much! Talk soon.
Wow thanks for this awesome write up this will be sure to help many people in the future as these Workhorse's began to age.
@@ktoutdoor Glad you liked it. One thing I forgot to mention was that my fuel gauge now seems to be reading much more accurately. The old pump read high - so that if my dash gauge showed 1/2 tank it probably only had 3/8's - maybe. And then my tank reading would go down very quickly once it read 1/4 tank. Plus - my Gen would not run even with the gauge reading over 1/4 tank - meaning the true fuel level was below it's PU point. But the new pump seems to offer much more realistic readings. Just another benefit.
I now understand the issue regarding the line release tool. I have run into that issue of the center line connection. Truth be told I was replacing the pump unit because it had failed so I simply cut the plastic nipple then used the release tool and needle nose pliers. Great idea with the treaded rod to lower the tank.
Thank you for contributing Larry, good idea about cutting off the old nipple
Great video Kevin... 👍 And I thought I was long winded.😄
The only other suggestion would be to replace all the hoses and clamps if possible.
Lastly, I have drilled, tapped and installed a setscrew to secure a nut.
Yes there are safer ways I got lucky
Really like your video, but as smart as you are I figured you would have cut a hole through the floor boards to get to the fuel pump. As soon as I can figure out where my fuel pump is located on my tank I'm going to try the floor board removal.
I new I had that option on our rv but its a very rare option. I just wanted to show that anyone can lower the tank themselves and replace the fuel pump. Plus it made for a cool video.
Great video, its very nice to know what to expect; Here's how my replacement differed from the motor home you demonstrated. I have a 2004 Tiffin Allegro, with HWH leveling jacks. At 106K miles per your advice I replaced my pump. My fuel pump still worked so I emptied the tank and used 2 floor jacks to lower the tank. First difference is the cross support for the leveling jacks prevented the tank from dropping down in the front. Second the line to the generator was 1/4" tubing, running across the top of the front two fuel tank straps, this prevented the tank from dropping down enough to do access anything. I had to remove the top portion of the 2nd (from front) tank strap to get access to the fitting. This was quite a challenge to hold the nut ... which I welded onto the strap before putting it back in place. I replaced the tubing with a hose, (after turning the fitting away from the strap as you suggested). I have no idea how I could re-install with the tubing. Third, my fill tube didn't have any side to side movement. I had to cut out some sheet metal to get the filler pipe removed. Fourth, the plugs on the opposite side of the tank had the clamps screws facing up! Fortunately the tank does come out with them attached. The trick to get the center fuel line off the pump was invaluable! It actually came off easier than the outside line. THANKS!
Thank you for contributing your story. I'm glad you got it done. 👍
Thank you for sharing this, it was very helpful.
Thanks for watching
Great video. Thank you Kevin.
appreciate you Kevin! hope you are well.
Finer than a frogs hair split 4 ways
Great video, thanks so much!
You're a saint! Thanks so much for this video! I just replaced my fuel pump and this video was the manual!
Thank you for the kind words I'm glad you found it helpful. Have a blessed day.
Good information Kevin
I have a Damon Intruder, floor plan 350. This model has plenty of room to replace the fuel pump without dropping the tank. I got right up in there no problem. Could be done roadside if you had a pump and the disconnect tools.
That could be a big time saver for sure
Thanks for all your videos they’ve been so helpful to me since I bought my unit have a Fleetwood Y 26 they didn’t build many of them a little quick steering but I really like it 9 1/2 mile to the gallon towing
Sweet 9.5 mpg thanks for watching
Thank you so much.. I love all your videos.. please keep them coming.. thank Mr. K..
Stay tuned more to come
Per Usual Well Done. "Salute"
Awesome dude…. Genius!
Thanks for taking the time for making the video, I really like your fuel tank drop kit, would it be any easier to have more room, maybe making your all thread 24"? Great job on the time lapse of lowering the tank
Another great video .
Thanks for watching Buddy
Great video
Thanks for watching
Great video and information..👏👏
Thank you
Thank you for this wonderful video!
I am currently trying to solve a backfire/misfire condition under load in my 06 Winnebago Adventurer 38J and may replace my fuel pump as a matter of maintenance. You video is extremely informative. I plan to install a fuel pressure gauge to monitor the fuel pressure under load / backfire/misfire conditions. Any advice is always appreciated.
Text me so I can call you back at 606-875-0125. Kevin
Very cool video
Thanks for watching
Fun level is 0. Necessary level 10. I understand the threaded rods now. Since I wasn’t going to use the old pump I would have cut off the center connection. Motorcycle jack would come in handy?
One this did was cut away the material between hose connections,made removing them easier. Dremel tool
Hi Kevin, your videos are great and give me more confidence in my mechanical skills. I bought a 2004 Fleetwood Bounder, W22 8.1LT Vortec with only 19,000 km on the clock last year, I drove it home from the seller and then ran into some medical issues that prevented me from doing anything with it. My son had been starting it and the generator periodically but hasn't been able to start it since last winter(very cold here in Canada.. The generator is running perfectly when fully loaded. The fuel pressure tested at the rail is a fraction below 58 when bypassing the fuel pump relay (good trick). I read that the pressure should be between 58 and 62, but I'm not sure if that's while the engine and fuel pump are running or just the fuel pump. With the key off, the pressure holds at 50 for quite some time. Any thoughts would be very much appreciated. Thanks again for the videos.
Rob
Text or call me at 606-875-0125 Kevin so we can chat.
Where did you get the switch accessory that plugs into the relay socket? Super video!
HERE YOU GO
www.ebay.com/itm/275425917734?hash=item4020a9fb26:g:mvsAAOSwwcpi~OCz&amdata=enc%3AAQAHAAAA0Ck7%2Bf3GV4oIInozhpYEbCV4r2aAFOQa5KNIWzqGTdjOggugf9vRj8sOFxRfv0wDFejOUt9%2B07efGb%2BJXm%2B06T%2ByPkwhdcFl5RQ4cykKA1Orss26CX9crvMh7bgJFDFoQKDnL5jP0HAi3aXO8txL%2BUZGAO%2FVbgnHLJnZw3NlDl6THhTWfo2Am6awXL67RBjvnQyexXF2%2FtZU1XE7JrQuWDunAJupd9KDl5d5I41To%2FFpJhwh92xRtSEQufS3wPem6hVi49cNRYGe5f%2FrmZtuwu0%3D%7Ctkp%3ABFBMtJetud1g
Having issue where Ford 1994 F53 460 V8 Fuel injected where driving up the mountains i come to a stop light and the engine vapor locks. Wont run for 4 + hours then it will start and run again. My gues not enough duel pressure but i dont know for sure?
To confirm I would get me a fuel pressure tester that you can screw on to the fuel rail to see if you loose fuel pressure at the time of vapor lock. check out this video czcams.com/video/fSPElyvqWiU/video.html
That was a great video thank you Kevin. I have a 35U 2005 Winnebago Voyage 8.1 L looks like the same size fuel tank you got my question would be is my fuel pump accessible by cutting through the floor like you did! Does the fuel pump sits squarely in the middle of the tank? Thanks, Terry
Yes I'm pretty sure it is in the center.. measure twice cut once...lol
Be careful. On my Adventurer model 37b there is a water tank directly above most of my fuel tank. So cannot cut an access panel. Wish I could, but the point is that every model is different, so the only thing can do is carefully inspect your construction and measure to see if there is space to cut this, and to see if you have actual, real access your pump if done.
I had mechanic replacing my gas pump, but he forgot to connect the generator gas line to the new gas pump. Can you tell me if I can connect it without drop the entire tank? I have class A Winnebago
I don't think the generator fuel line connects to the fuel pump it should have its own connection check out this video czcams.com/video/A4CWz2e3Vvs/video.html
Let me know what you find out.. My cell 606-875-0125
I have a question, is the voltage at the pump 12v positive or 12 negative? The thing is that I am measuring the voltage that arrives and if I measure it with the normal meter (+/+ and -/-) the voltage drops and if I measure it (+pump - meter and - pump + meter) the voltage rises but in a negative reading . I appreciate your response.
Give me a call 606-875-0125 Kevin
I wonder is there a way that you can check the fuel gauge sending unit without dropping the tank?
Yes you can czcams.com/video/SOaDoPpmpFY/video.html
Or by a scangauge 3 I think it will work also amzn.to/3YpKteo
Also test your dash cluster here czcams.com/video/ZMIcl2GjK1A/video.html
since its a throwaway part why not just cut the web enough to get the removal tool in position.
drilla 3/16 hole thru the lock nut and all thread and put a cotterpin thru it
Hi Kevin & go info. I have a 2005 Newmar Mountain Aire 3778 on the workhorse chassis w24 with 63000 miles. It runs great but I was considering having a new oem fuel pump installed. My question is do you know any reliable mechanics in the Jacksonville area of Florida. Kenny
Sorry for the delay. But i don't know of any
Where did you get that cool relay with the switch?
HERE YOU GO
www.ebay.com/itm/275425917734?hash=item4020a9fb26:g:mvsAAOSwwcpi~OCz&amdata=enc%3AAQAHAAAA0Ck7%2Bf3GV4oIInozhpYEbCV4r2aAFOQa5KNIWzqGTdjOggugf9vRj8sOFxRfv0wDFejOUt9%2B07efGb%2BJXm%2B06T%2ByPkwhdcFl5RQ4cykKA1Orss26CX9crvMh7bgJFDFoQKDnL5jP0HAi3aXO8txL%2BUZGAO%2FVbgnHLJnZw3NlDl6THhTWfo2Am6awXL67RBjvnQyexXF2%2FtZU1XE7JrQuWDunAJupd9KDl5d5I41To%2FFpJhwh92xRtSEQufS3wPem6hVi49cNRYGe5f%2FrmZtuwu0%3D%7Ctkp%3ABFBMtJetud1g
Kevin, why did you pull/jump the relay instead of just depressurizing, hooking on to Shrader valve, and then turn the key but not to start?
Extra safety step.. Key on no start still applies power to the fuel pump for a brief second. I was also forcing the pump on in order to pump out excess fuel from the tank.
@@ktoutdoor thank you
Kevin, do you have any info on the "new toy" of yours that temporarily replaces the fuel pump relay for siphoning gas thru the fuel rail? Maybe an Amazon product? Thanks Larry in Washington
Here you go amzn.to/3Lnra1C If your careful you can also just use a wire to jump wire the fuel pump to power up.
or google the number 9036-1 IPA Sm Relay Bypass Switch
Kevin! can you tell me where is the gas line from the generator is connected?
This video will show you czcams.com/video/A4CWz2e3Vvs/video.html
Got it! So looks like the generator line has its own connector. The guy installed my new gas pump forgot to connect that line. Do you think that I will need lower the tank to connect ?
I want to do myself
@@sotam1973 Yes if I can do so can you!! Just follow the video you just have to lower it enough to put the line back on.
@@ktoutdoor I like your way to lower the tank. Can you send me the hardware information?
I Hate how these manufacturers are not smart enough to make a damn access panel like in some small vehicle
I think I will use a motorcycle jack
Great video! Thanks!!!
Thanks for watching