Well, here's another fun chapter in my ongoing RV adventure novel titled "Things That Break When You're Not Looking." My Kwikee steps have decided to play dead - they're stuck about 90% retracted and won't budge when I open the door, though the amber light cheerfully illuminates like it's mocking me.
I'm pretty sure this is either a motor that's given up the ghost or something's binding up in the linkage, but I'd love some confirmation before I start throwing parts at it. Should I be checking for 12V at the motor first, or am I overthinking this? And while we're at it, any preventive maintenance I should do to keep this from happening again? Because apparently my RV has commitment issues with working components.
Kwikee steps stuck retracted with amber light usually indicates motor failure or linkage bind. Check 12V at motor first. If power present but no movement, replace motor. Lubricate linkage as preventive maintenance.
Your Kwikee steps are experiencing a classic controller issue where they're getting stuck at 90% retraction and won't respond to door signals. The fact that the amber light activates when you open the door shows the door switch is working, but the controller isn't processing the extend command properly when the steps are in that partial position. Your instinct about the controller is spot-on - this is typically caused by a faulty control module that's not reading the step position sensor correctly or has developed internal relay problems. The temporary fix of manually lifting the steps to full retraction before opening the door confirms the controller works when it gets a proper "fully retracted" signal, but fails when receiving the intermediate position reading.
This specific symptom pattern - steps stopping at 90% retraction, amber light functioning, but no response to door opening until manually positioned - points directly to either a failing Kwikee control module (part number varies by Kwikee series - check controller label or consult dealer with RV model/year) or a dirty/damaged step position sensor. Controller replacement costs vary by series ($150-400+ depending on model), while cleaning the position sensor costs nothing but 30 minutes of your time. Start with the sensor cleaning since it's the most common culprit and requires no parts.
Your Kwikee step system relies on three key components working in harmony: the door switch, the step position sensor, and the control module. When you open your RV door, the door switch sends a signal to the controller (voltage and switching method varies by model), which then checks the step position sensor to determine if the steps need to extend. In your case, the door switch is clearly working (evidenced by the amber light), but the controller is misreading the step position when they're at 90% retraction.
The reason your steps work normally when you manually lift them to full retraction is that the position sensor can clearly detect the "fully retracted" position, sending a clean signal to the controller. However, when the steps are sitting at that 90% position, the sensor is likely giving an ambiguous reading - not quite "fully retracted" but not "extended" either. This puts the controller in a confused state where it doesn't know whether to extend or retract, so it does nothing.
Kwikee step position sensors commonly collect dirt, road grime, and moisture over time, especially after sitting in storage. The specific sensor type varies by model year - some use magnetic reed switches while others use hall effect sensors - but both read the position of a magnet attached to the step mechanism. When contaminated, these sensors give inconsistent readings that confuse the controller logic.
The fact that your steps close to exactly 90% when the door closes is also telling. This suggests the controller is receiving a "partially extended" reading and trying to retract them, but something is preventing full retraction - possibly the same sensor contamination issue or a mechanical binding problem. The controller times out the retraction cycle when it doesn't receive the expected "fully retracted" signal within its programmed timeframe.
Storage environments are particularly hard on these systems. Temperature cycling, humidity, and lack of use can cause contacts to corrode, seals to fail, and lubricants to thicken. Your symptoms are classic for a system that's been sitting unused, where the step mechanism has developed just enough resistance to prevent full retraction, while the position sensor has collected enough contamination to give false readings.
WARNING: Always disconnect power at the RV's main panel before working on electrical components. Note that disconnecting power may reset controller memory on some models, requiring recalibration after repairs. Steps support significant weight - never place hands or body parts under steps during operation or testing.
IMPORTANT: Locate your Kwikee model number on the controller or step mechanism before beginning. Different series (3000, 4000, 5000, etc.) use different components and procedures.
For this repair, you'll need a basic set of tools and cleaning supplies that most RV owners should have on hand. The electrical testing equipment is optional but highly recommended for confirming your diagnosis before ordering parts.
Essential tools include a multimeter capable of reading 12V DC voltage and continuity, which will help you test the door switch and controller outputs. You'll need a basic socket set with 10mm and 13mm sockets for accessing the step mechanism and controller mounting. A good set of screwdrivers, both Phillips and flathead in various sizes, will be necessary for removing covers and accessing connections.
Cleaning supplies are critical for this repair. Get electrical contact cleaner (CRC QD Electronic Cleaner or similar), white lithium grease for lubricating the step mechanism, and dielectric grease for protecting electrical connections. You'll also want shop rags, a small wire brush, and compressed air if available.
Safety equipment shouldn't be overlooked. Safety glasses are essential when using compressed air and cleaners, and work gloves will protect your hands from sharp edges and chemicals. A flashlight or headlamp will help you see into the tight spaces around the step mechanism.
If you determine the controller needs replacement, have your RV's model year and step system information ready. Kwikee controllers are model-specific, and ordering the wrong one is a common and expensive mistake. Take a photo of the existing controller's label before removal to ensure you get the correct replacement part for your model (verify with dealer).
WARNING: Ensure RV is level and stable. Use wheel chocks and stabilizer jacks. Never work under partially extended steps.
Start your diagnosis by locating and inspecting the step position sensor, which is typically mounted on the step mechanism frame near the pivot point. With the steps in their problematic 90% retracted position, examine the sensor and the magnet or actuator that triggers it. Look for obvious contamination, corrosion, or mechanical damage. The sensor should be clean and the actuator should move freely.
Clean the position sensor thoroughly using electrical contact cleaner and a soft brush. Remove any built-up road grime, grease, or corrosion from both the sensor body and the actuating magnet or arm. Pay special attention to the gap between the sensor and actuator - this should typically be 1/8 inch or less for proper operation. If the gap is too large due to bent mounting brackets or worn components, adjust or repair as needed.
Test the door switch operation with your multimeter. With the RV door closed, you should read battery voltage (around 12.6V) at the door switch output wire. When you open the door, this voltage should drop to near zero. If the door switch isn't working properly, the amber light wouldn't illuminate, so this test mainly confirms your electrical connections are solid.
Manually cycle the steps through their full range of motion while monitoring the position sensor. With the steps fully retracted, the sensor should show continuity (closed circuit). As the steps extend, the sensor should open the circuit. If the sensor doesn't change state clearly at the fully retracted position, it needs replacement or further cleaning.
Lubricate the step mechanism pivot points and slides with white lithium grease. Stiff or binding mechanical components can prevent the steps from reaching their fully retracted position, causing the controller to time out and leave them partially extended. Work the steps manually through several full cycles to distribute the lubricant and ensure smooth operation.
If cleaning and lubrication don't resolve the issue, proceed to test the controller. With power restored and the door closed, measure voltage at the controller's step motor output terminals. You should see 12V when manually triggering the door switch. If voltage is present but steps don't move, the motor or mechanical linkage has failed. If no voltage is present, replace the controller module. resolve the issue, test the controller outputs. With the steps manually positioned at full retraction and the door open, the controller should output 12V to the step motor extend circuit. You can test this by measuring voltage at the motor connector. If you're not getting the proper voltage output, the controller has failed and needs replacement. expected voltage output from the controller when conditions are correct for step extension, the controller has likely failed internally.
Controller replacement involves disconnecting the wire harness, removing the mounting screws, and installing the new unit. Before disconnecting anything, take detailed photos of the wire connections, as Kwikee controllers use specific wire colors that must be matched exactly. The controller is typically mounted in a protected location near the steps, often behind a plastic access panel. Torque all fasteners to manufacturer specifications.
After installing a new controller or completing cleaning and lubrication, test the system thoroughly. Start with the steps fully retracted and door closed. Open the door - steps should extend fully within 15-20 seconds. Close the door - steps should retract completely within the same timeframe. Repeat this cycle several times to ensure reliable operation.
If the steps still stop at 90% retraction after all these steps, you likely have a mechanical binding issue in the step mechanism itself. This could be worn bushings, bent linkages, or a failing motor that can't generate enough torque to complete the retraction cycle. These problems require more extensive disassembly and potentially professional repair.
While cleaning the position sensor and basic troubleshooting are well within most RV owners' capabilities, some aspects of Kwikee step repair require professional attention. If your testing reveals that the step motor itself is drawing excessive current or making unusual noises, internal motor problems require specialized tools and knowledge to repair safely.
Electrical issues beyond basic controller replacement can be tricky to diagnose without proper test equipment and wiring diagrams. If you're seeing inconsistent voltage readings, intermittent operation, or signs of electrical burning or melting, stop your DIY efforts and consult a qualified RV technician. Electrical problems in RV step systems can create safety hazards or cause expensive damage to other systems if handled improperly.
Mechanical problems with the step linkages, pivot points, or mounting hardware often require welding or precision machining to repair correctly. Attempting to bend or force damaged components can create safety hazards where steps might fail unexpectedly. If you discover cracked welds, severely worn bushings, or bent structural components, professional repair is the safest option.
Controller programming and advanced diagnostics are another area where professional help is valuable. Some Kwikee controllers have adjustable timing parameters and diagnostic modes that require specific procedures to access. If standard troubleshooting doesn't resolve your issue, a technician with Kwikee-specific training and diagnostic equipment can often identify problems that aren't obvious to DIY repairs.
Consider professional repair if your RV is still under warranty, as DIY electrical work might void coverage. Many RV dealerships have technicians specifically trained on Kwikee systems and access to updated technical bulletins and recall information that could affect your specific model year and system configuration.
The cost of professional diagnosis is typically $100-150, while complete step system overhaul can range from $500-800 depending on what components need replacement. Weigh these costs against your comfort level with electrical and mechanical repairs, and the potential safety implications of steps that don't operate reliably. Remember that RV steps support significant weight and must function properly for safe entry and exit from your coach.
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