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Onan 5500 Generator Problems: Complete Repair Guide 2024
Engine Medium 2-6 hours 289 👍 1

Onan 5500 Generator Problems: Complete Repair Guide 2024

Spent three hours testing my 2014 Hurricane's Onan 5500 gen getting 11.8 volts output when every manual says it should be 12+ volts! Here's the weird part - when I disconnect the remote harness, the generator fires right up and purrs like a kitten. But the second I plug that remote connection back in, boom - both the remote start light AND the generator start light come on, and then... nothing. Won't start at all.

The really bizarre symptom is this chattering from the fuel pump when the remote is connected. I can literally feel the fuel line jumping around when I put my hand on it. It's like the pump is having some kind of seizure or something!

I'm guessing this has to be some kind of electrical issue between the control board and the remote system, but I've never seen anything quite like this before. Anyone dealt with this specific combo of symptoms on an Onan 5500? Really hoping there's a known fix because pulling this thing out of the RV again would be a major pain! …more
Ford V10 Triton Engine Maintenance Guide: EGR Delete vs Regular Service Tips
Engine Easy N/A 164 👍

Ford V10 Triton Engine Maintenance Guide: EGR Delete vs Regular Service Tips

Spent years doing regular EGR maintenance on my old gas motorhome without issues — but this 2007 Fleetwood 31' Tioga with Ford V10 Triton has me second-guessing everything. I keep reading conflicting information about EGR delete procedures on V10 engines, and I'm worried I might make things worse if I mess with it.

Is the EGR delete modification actually necessary on this 2007 3-valve V10, or am I overthinking this? I don't want to void any warranties or create problems that weren't there before. Would I be better off just sticking to regular maintenance instead of modifications? I'm looking for reassurance that I'm taking the right approach to keep this engine running reliably for years to come. …more
Ford E450 V10 Reliability: Expected Mileage and Longevity Guide for RV Owners
Engine Easy 1-2 hours inspection 146 👍

Ford E450 V10 Reliability: Expected Mileage and Longevity Guide for RV Owners

Nobody prepared me for staring at this 2018 Jayco Greyhawk 29MVP with Ford E450 chassis showing 54,000 miles and wondering if I'm looking at a money pit. The unit appears well-maintained with quality features including auto-leveling, fiberglass roof and nose, plus J-ride suspension. However, the odometer shows 54,000 miles, which exceeds my initial target range.

I need to assess whether this mileage represents significant wear on the E450/V10 drivetrain combination. What is the typical service life expectation for these engines when properly maintained? At what point should mileage become a primary concern versus overall mechanical condition? …more
Ford E-350 vs E-450 Chassis: RV Fuel Economy, Power & Weight Capacity
Engine Easy N/A 130 👍

Ford E-350 vs E-450 Chassis: RV Fuel Economy, Power & Weight Capacity

Last weekend I felt this awful engine strain and heard sluggish acceleration sounds while test-driving a 2017 Phoenix Cruiser #2351 with its E-350 chassis and V10 engine. I'll be doing extensive western touring through mountain and plains regions, which means substantial mountain grades and wind challenges. I'm comfortable driving slowly and want to understand two key things: 1) Will this E-350 chassis handle mountain grades without major issues, and 2) What's the real-world fuel consumption like? I plan to do an initial inspection this weekend, followed by a third-party mechanical review. I'm not overly concerned about fuel economy but want to understand the actual performance limitations. I'd appreciate insights from owners who have experience with similar touring conditions on an E-350 chassis. …more
5 Star Tuner X4 for Ford V10 RV: Complete Performance & Upgrade Guide
Engine Easy 15 minutes 105 👍

5 Star Tuner X4 for Ford V10 RV: Complete Performance & Upgrade Guide

Planning to tune my 2018 Ford 6.8L V10 RV but got quoted $800 for professional tuning and wondering if the 5 Star X4 is DIY-friendly. Specifically want to know about real-world performance improvements - does it actually improve throttle response and shift points? What about fuel economy gains?

Which of the 3 programs works best for RV towing? Is the investment worth it for better drivability or just hype? …more
Onan 4000 Generator Surging: Step-by-Step Fix Guide (2024)
Engine Medium 2-3 hours 103 👍

Onan 4000 Generator Surging: Step-by-Step Fix Guide (2024)

Despite my neighbor's Onan 4000 generator purring like a kitten, mine suddenly developed nasty surging issues yesterday — what's going wrong? It surges when cold, then settles down as it warms up. Under load it surges heavily until the appliance shuts off. Getting worse each day.

What are the main causes of generator surging? Need a step-by-step approach to diagnose and fix this - should I start with the carburetor, fuel system, or something else? …more

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Onan Code 36 Fix: Complete Troubleshooting Guide for RV Owners
Engine Medium 2-3 hours 98 👍

Onan Code 36 Fix: Complete Troubleshooting Guide for RV Owners

Got my tools spread out and I'm determined to fix this Onan QP 3600 LP generator (Model 3.6KY-26120R) that's throwing code 36 myself — where's the best place to start? The unit starts immediately but shuts down right away. I have plenty of propane and the oil level is fine.

What specifically does code 36 indicate on Onan LP generators? What are the most common causes that would make this code appear? …more
Cummins ISL Code 1896: EGR Valve Controller Gaskets & Repair
Engine Medium 3-4 hours 97 👍

Cummins ISL Code 1896: EGR Valve Controller Gaskets & Repair

About to drop $2,800 on my Cummins ISL throwing code 1896 for EGR valve controller out of calibration and wondering if I can tackle this myself. Planning to pull and clean the EGR valve controller to see if that clears it up.

Do I need to order replacement gaskets before I start this job? Want to make sure I have everything on hand before I tear into it. …more
Onan 5500 Generator Shuts Down Under Load: Troubleshooting Guide
Engine Medium 2-3 hours 97 👍

Onan 5500 Generator Shuts Down Under Load: Troubleshooting Guide

Onan 5500 runs perfectly at idle but kills itself within 30 seconds of turning on the AC. Been fine for years and suddenly can't handle any real load. Fuel filter is new, oil is fresh, and it starts right up every time — just dies the moment I ask it to actually work. …more
Onan Generator Fault Codes: Complete Troubleshooting Guide for RV Owners
Engine Medium Varies by issue 94 👍

Onan Generator Fault Codes: Complete Troubleshooting Guide for RV Owners

During my latest camping trip my Onan generator threw a fault code — got my multimeter ready and just need to figure out which diagnostic approach will crack this thing.

I'm seeing 12 or 13 blinks on my generator error display and want to understand what these codes might mean. Are these codes consistent across different Onan models? I'm hoping it's a minor issue and not something requiring a major repair.

Can anyone help me decode what these blinking fault codes typically indicate? …more
Ford F53 V10 Bypass Oil Filter Installation: Best Mounting Locations for RV Chassis
Engine Medium 1-2 hours 94 👍

Ford F53 V10 Bypass Oil Filter Installation: Best Mounting Locations for RV Chassis

Walked out to check my oil analysis results and they're showing 15-micron contaminants, but everything says my 2003 F53 V10's factory filter catches down to 25 microns. I've been reading about how these can help extend oil life and keep things cleaner, but I'm honestly not sure where the best place to mount one would be.

I've seen some people mention sandwich adapters at the original filter location, remote mounting blocks, and even tapping directly into the engine block. As someone who's still learning, I don't want to mess this up or create problems down the road. What's considered the best practice for mounting location on the F53 V10? I'd really appreciate some guidance from those who have done this before. …more
Onan 5500 Generator Tune-Up Guide: Best Aftermarket Parts & Filters 20
Engine Medium 2 hours 90 👍

Onan 5500 Generator Tune-Up Guide: Best Aftermarket Parts & Filters 20

Before my last camping trip when I tried to order replacement parts, I discovered that finding genuine OEM components for my Onan 5500 generator has become nearly impossible. The Cummins website has been showing most tune-up components as out of stock for months now, and when I do find supposedly "official" Onan oil filters online, many retailers are substituting generic filters that may not meet the same specifications.

I've been researching alternatives and I'm particularly concerned about getting the right oil filter and spark plugs. For the oil filter, I've seen conflicting information about whether aftermarket options like Wix filters are truly compatible - some sources mention the 57398 but I've read mixed reviews about fitment issues. For spark plugs, my current ones are NGK BPR4EY, and I've heard the NGK 3432 might be equivalent, but I want to make sure before ordering.

I'm also planning to stick with zinc-containing oil like Rotella T6 15w40 since I know air-cooled engines need the extra protection, but I'd love confirmation that I'm on the right track with quality aftermarket parts that won't compromise my generator's performance. What specific part numbers and brands would you recommend for a reliable tune-up when OEM parts aren't available? …more
How to Diagnose RV Hard Starting Problems: Fuel System Troubleshooting Guide
Engine Medium 1 hour 90 👍

How to Diagnose RV Hard Starting Problems: Fuel System Troubleshooting Guide

RV cranks for 10-15 seconds before finally firing up, and it's getting worse each week. Used to start on the first crank every time. Fuel pressure seems low at the rail but I'm not sure if it's the pump, filter, injectors, or something else entirely in the fuel system. …more

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Banks Pedal Monster Ford F53 Motorhome Review: Does It Really Work?
Engine Easy N/A - informational 88 👍

Banks Pedal Monster Ford F53 Motorhome Review: Does It Really Work?

Halfway through every camping season, I find myself second-guessing whether that Banks Pedal Monster I installed on my 2017 F53 chassis motorhome was worth it. After installation, I'm honestly not feeling much difference in performance, even in the most aggressive setting. The sales literature made it sound like it would dramatically improve acceleration and power.

I'm worried this expensive modification isn't actually doing anything meaningful for my heavy motorhome. Should I be feeling more power by now, or did I just throw money away? I'm starting to think maybe these throttle controllers don't actually work on big RVs like they claim to. Can someone help me understand what this thing is supposed to actually do versus what it can realistically deliver on an F53 chassis? …more
How to Fix Onan QD3200 Diesel Generator Fuel Leak Behind Air Filter
Engine Medium 1-3 hours 86 👍

How to Fix Onan QD3200 Diesel Generator Fuel Leak Behind Air Filter

According to Murphy's Law, my Onan QD3200 generator is doing something bizarre — it's leaking diesel fuel from behind the air filter instead of where you'd normally expect fuel leaks. The fuel appears to be coming from somewhere behind the air filter box, and I'm worried about making things worse if I don't diagnose this properly. I've shut everything down for now because I'm nervous about safety issues.

I need to know the safest way to trace where this leak is actually coming from without creating a fire hazard or damaging anything. What are the most likely culprits in that area, and what's the proper procedure to identify the exact source? I want to make sure I approach this methodically rather than just poking around and potentially making the problem worse. …more
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