HWH Leveling System Pump Failure: Diagnosis and Repair Guide

Quick Take

Yes, HWH pump failures are unfortunately more common than they should be, and you're not alone in experiencing this expensive problem. Your scenario - shuttle valve replacement followed by pump failure shortly after - suggests the pump was likely already compromised internally when you replaced the shuttle valve. The zero discharge pressure confirms complete internal pump failure, likely worn pistons, seals, or valves. At $5,000 for replacement, many RV owners are making the same calculation you are about whether the leveling system is worth maintaining.

Common Causes

HWH pump failures can result from several interconnected issues. Contaminated hydraulic fluid is a major culprit - dirt, moisture, or metal particles circulating through the system accelerate wear on internal components like pistons, seals, and check valves. When your shuttle valve failed initially, it likely introduced debris into the system that damaged the pump.

Heat cycling also takes a toll on these pumps. The constant expansion and contraction of seals and metal components eventually leads to internal leakage and pressure loss. Age is another factor - pumps over 10-15 years old frequently develop internal wear that can't be economically repaired.

Overuse can also contribute to premature failure. If the system has been cycling frequently due to small leaks or worn components elsewhere, the pump experiences excessive runtime that shortens its lifespan significantly.

Preparation

Before writing off your HWH system entirely, gather some key information to make an informed decision. Document the age of your system and pump - if it's over 15 years old, replacement may not be cost-effective. Check with multiple HWH dealers for pump pricing, as costs can vary significantly between suppliers.

Research the availability and cost of rebuilt pumps, which typically run $2,500-3,500 versus $5,000 for new. Some specialty hydraulic shops can rebuild HWH pumps for even less, though turnaround time may be longer.

Consider your RV usage patterns and camping style. If you primarily stay in developed campgrounds with level sites, the leveling system may be less critical. However, if you boondock frequently or prefer unlevel sites, functioning jacks provide significant convenience and safety benefits.

Get quotes for complete system removal if you're leaning toward abandoning the HWH setup. The weight savings alone - varies significantly by system configuration (consult manufacturer specs for your specific model) - can improve fuel economy and handling.

Repair Steps

⚠️ SAFETY WARNING: Hydraulic systems operate under extreme pressure (typically 2,000-2,500 PSI). Always relieve system pressure completely before disconnecting any lines. Wear safety glasses and gloves when working with hydraulic fluid, which can cause skin and eye irritation. Never attempt to stop leaks with your hands - high-pressure hydraulic fluid can penetrate skin and cause serious injury requiring immediate medical attention.

If you decide to pursue repair, start by getting a second opinion on the pump diagnosis. Have another technician check hydraulic fluid level and condition, verify zero discharge pressure, test pump motor operation (electrical continuity, amperage draw), and check for internal leakage. Sometimes what appears to be pump failure is actually a stuck relief valve (check pressure setting per manufacturer specs) or severely contaminated fluid.

For a confirmed pump failure, source a rebuilt unit rather than new if budget is a concern. Reputable rebuilders like Applied Power or regional hydraulic shops often provide 1-2 year warranties on rebuilt HWH pumps. Expect 2-4 weeks lead time for rebuilding services.

When installing any replacement pump, completely flush the hydraulic system with clean fluid. Replace all filters and check hoses for internal contamination. This step is critical - installing a new pump in a contaminated system almost guarantees repeat failure.

After installation, run extended test cycles to verify proper operation and check for leaks. Monitor the system closely during your first few trips to ensure the repair holds up under actual use conditions.

When to Get Help

Given the complexity and cost involved, professional diagnosis is essential before making repair decisions. Your mobile tech sounds competent, but consider getting a second opinion from an HWH authorized service center if one is accessible in your area.

If you're not experienced with hydraulic systems, pump replacement should be handled professionally. The job involves system bleeding, pressure testing, and torque to manufacturer specifications that can cause expensive damage if done incorrectly.

For system removal, professional help is advisable to properly disconnect hydraulic lines, electrical connections, and mounting hardware. Many components are heavy and awkward to handle safely.

Consider consulting with other RV owners who've faced similar decisions. RV forums and owner groups for your specific RV model often provide valuable insights about long-term costs and alternatives to factory leveling systems.