Kwikee RV Steps Not Working? Complete Troubleshooting Guide (2024)

Bottom Line Up Front

Pete, since your Kwikee steps extend fine but won't retract without manual assistance (even after replacing the gearbox and motor), you're dealing with a mechanical binding issue rather than an electrical problem. The fact that they retract a quarter inch then stop indicates the motor has power and the gearbox is engaging, but something is physically preventing full retraction. Common causes include misaligned step arms, worn pivot bushings, or debris in the step mechanism preventing smooth operation.

Root Causes

With a new gearbox and motor installed, the issue is likely mechanical binding in the step mechanism itself. Common causes include worn or damaged pivot bushings at the step arm connection points, which create excessive friction during retraction. Step arms can also become slightly bent or misaligned during installation or use, causing them to bind against the mounting brackets.

Another frequent culprit is debris buildup in the step rails or around the pivot points. Road grime, leaves, and dirt accumulate over time and can prevent smooth retraction. Additionally, if the step linkage wasn't properly lubricated after the gearbox replacement, metal-on-metal contact creates enough resistance to overwhelm the motor during retraction.

The quarter-inch movement you're seeing suggests the motor and gearbox are working correctly - they have enough power to start the retraction process but can't overcome the binding that occurs as the steps fold up. This points to issues with the mechanical linkage rather than the drive components you've already replaced.

Before You Start

SAFETY WARNING: Disconnect power to the step motor before beginning any work. Use wheel chocks and ensure the RV is on level ground.

You'll need basic hand tools including a socket set, wrenches, penetrating oil (like PB Blaster), white lithium grease, and a flashlight or work light. Since you've already done the gearbox and motor replacement, you're clearly comfortable with this level of work.

Before starting any work, disconnect the power to the step motor by removing the appropriate fuse from your RV's fuse panel (typically labeled 'STEPS' or 'KWIKEE') or turning off the circuit breaker if so equipped to prevent accidental activation. Test the steps manually by gently pushing them in and out while disconnected - this will help you identify exactly where the binding occurs. Pay attention to any grinding, scraping, or unusual resistance at specific points in the travel.

Take photos of the step mechanism before disassembly, especially the linkage connections and alignment. Since you recently installed the gearbox, double-check that all mounting bolts are torqued to manufacturer specifications (see manufacturer specifications for your specific model) and that nothing shifted during installation. Have replacement bushings on hand (correct part for your model - verify with dealer) as these are often the culprit.

The Repair Process

Start by thoroughly cleaning all visible parts of the step mechanism with degreaser and a wire brush. Remove any accumulated debris from the step rails, pivot points, and around the gearbox mounting area. Spray all pivot points and linkage connections with penetrating oil and let it soak for at least 30 minutes.

Next, inspect all pivot bushings at the step arm connections. These bushings (typically plastic on most Kwikee models) wear out over time and create binding when they become oval-shaped or cracked. Remove the pivot pins and examine each bushing carefully. Replace any that show wear, cracking, or deformation. The bushings should slide smoothly on their pins without excessive play.

Check the alignment of both step arms by measuring their position relative to the mounting brackets. They should be parallel and move freely without contacting the RV body or each other. If an arm appears bent or misaligned, carefully straighten it or replace it entirely. Sometimes the mounting brackets themselves can shift, requiring repositioning.

After addressing any binding issues, lubricate all pivot points with white lithium grease. Reconnect the power and test the operation slowly, watching for any points where the mechanism hesitates or binds. The steps should now retract smoothly under motor power alone. If they still require assistance, there may be internal damage to the step arms or linkage that requires replacement.

Professional Help Needed

If the steps continue to bind after cleaning, lubricating, and replacing worn bushings, you may need professional assistance to diagnose internal damage to the step mechanism. A qualified RV technician can perform a complete step system evaluation, including checking for hairline cracks in the step arms or subtle misalignments that aren't obvious to the untrained eye.

Consider professional help if you discover that the mounting brackets have shifted or if the RV frame around the step mounting points shows signs of stress or damage. This type of structural issue requires specialized knowledge and potentially welding repairs that are beyond typical DIY capabilities.

Professional service typically costs $200-400 for step mechanism repair, depending on which components need replacement. Given that you've already invested in a new gearbox and motor, it's worth having a technician verify that these components are properly aligned and functioning correctly. Sometimes a small adjustment in mounting position can resolve persistent binding issues that seem mysterious to the owner.