Lippert Power Gear Slide Motor Replacement: Complete Guide to Parts &

Bottom Line Up Front

Yes, there are several companies that make direct replacement slide motors and gear assemblies for Power Gear/Lippert systems, and you're absolutely right to be frustrated with Lippert's parts pricing and support policies. Since you've identified that your slide motor/gearbox is getting weak and suspect it's just the brushes needing replacement, you have three viable options: aftermarket replacement motors from companies like Venture Manufacturing or Tuson RV Brakes that cost $200-400 instead of Lippert's $1000 complete assembly, sourcing individual motor brushes from electrical motor shops for approximately $15-30 (prices vary by motor size and supplier), or rebuilding the motor yourself with generic brushes from suppliers like Grainger or McMaster-Carr.

The most cost-effective solution for your situation is to either rebuild your existing motor with new brushes or purchase an aftermarket replacement motor. Companies like Venture Manufacturing, Tuson RV Brakes, and RV Slide Out Motors LLC specialize in providing affordable alternatives to Lippert's overpriced assemblies. These aftermarket motors typically run $200-400 complete and often come with better warranties than Lippert provides. If you're mechanically inclined enough to consider reverse engineering the system, you can definitely handle a brush replacement or motor swap.

Your assessment of the component costs is spot-on - these are indeed simple 12V DC permanent magnet motors with basic planetary gear reductions. The $1000 price tag from Lippert is pure markup on what should be standard industrial components. Many RV owners have successfully retrofitted their slides with aftermarket solutions, and the mounting patterns are often standardized enough that direct bolt-in replacements are available.

Root Causes

The weakness you're experiencing in your slide motor is almost certainly due to worn carbon brushes, exactly as you suspected. In 12V DC permanent magnet motors like those used in RV slide systems, the brushes are the primary wear item and typically need replacement based on inspection and performance, as intervals vary significantly with usage patterns and environmental conditions. Inspect brushes every 12-18 months or if you notice reduced slide performance - replace when brush length is less than 1/4 inch or contact surface is uneven. As brushes wear down, they make poor contact with the commutator, resulting in reduced power output, intermittent operation, and that characteristic "weak" feeling when operating the slide.

Carbon brush wear occurs through normal friction contact with the rotating commutator segments. Each time you extend or retract your slide, the brushes lose microscopic amounts of material. Environmental factors accelerate this wear - dust infiltration, moisture exposure, and temperature cycling all contribute to premature brush deterioration. RV slide motors are particularly susceptible because they're often mounted in exposed locations under the coach where they encounter road debris, temperature extremes, and moisture.

Secondary wear patterns include commutator scoring or glazing, which can occur when worn brushes aren't replaced promptly. If the commutator surface becomes rough or develops a glazed appearance from carbon deposits, new brushes won't seat properly and motor performance will remain poor. This is why it's important to address brush wear early rather than waiting until the motor barely functions.

The planetary gear reduction typically doesn't wear significantly unless the motor has been operated with severely worn brushes for extended periods. When brushes make poor contact, the motor can develop hot spots that stress the permanent magnets, potentially requiring more extensive repairs. However, in most cases where owners notice gradual weakening over time, the issue is isolated to brush wear and possibly minor commutator resurfacing.

Before You Start

Before diving into any repair or replacement work, you'll need to properly diagnose the motor and gather specific information about your slide system. Start by locating the motor assembly and documenting the model numbers, voltage ratings, and mounting configuration. Most Power Gear/Lippert slide motors have identification plates or stamped numbers that will help you source exact or compatible replacements.

Essential tools for this project include a digital multimeter, basic hand tools (screwdrivers, wrenches, pliers), electrical contact cleaner, fine-grit sandpaper or emery cloth, and safety equipment like safety glasses and work gloves. If you're planning to disassemble the motor for brush replacement, you'll also need small picks or awls for removing brush springs and possibly a bearing puller if the armature needs removal.

Safety considerations are critical when working with slide systems. Always ensure the slide is fully supported and cannot move unexpectedly during motor removal. Disconnect the battery or remove the fuse for the slide system before beginning any electrical work. Many slide motors have significant stored energy in their brake mechanisms from spring-loaded components. Before motor removal, engage the manual brake release (if equipped) or use proper spring compression tools to safely relieve spring tension. Consult manufacturer service procedures for your specific model's brake disengagement steps to avoid injury from sudden spring release.

Document the existing wiring configuration with photos before disconnecting anything. Slide motor wiring typically includes power, ground, and brake connections, and some systems have additional feedback circuits for position sensing. Proper reconnection is essential for safe operation. Also measure and record the slide's current draw during operation if possible - a weak motor often shows higher than normal amperage as it struggles to move the load.

Research your specific slide model's weight and extension length, as this information will be needed when selecting replacement motors. Slide motors are rated for specific load capacities, and using an undersized replacement can lead to premature failure or safety issues. Most Power Gear/Lippert slide motors range from 200-400 watts depending on the slide size and weight.

The Repair Process

For brush replacement in your existing motor, start by removing the motor from the slide mechanism and carefully disassembling the motor housing. Most RV slide motors use a simple two-piece housing held together with through-bolts. Once opened, you'll see the armature (rotor) with the commutator on one end and the carbon brushes held in spring-loaded holders.

Carefully remove the old brushes, noting their orientation and the condition of the brush springs. Measure the old brushes to determine the correct replacement size - common sizes include 1/4" x 5/16" x 5/8" for smaller motors and 5/16" x 1/2" x 3/4" for larger units. Generic carbon brushes are available from electrical supply houses, motor repair shops, or online suppliers like Grainger (part numbers vary by size but typically run $8-15 per pair).

Inspect the commutator surface while the motor is disassembled. Light scoring or discoloration can be addressed with fine sandpaper (400-600 grit) or crocus cloth, working circumferentially around the commutator. Deep scoring or significant pitting requires professional machining or armature replacement. The commutator surface should be smooth and even with clear separation between segments.

When installing new brushes, ensure they seat properly in their holders with the curved face matching the commutator surface and make full contact with the commutator surface. Install brushes with the same orientation as the originals (note any beveled edges or directional markings). New brushes may need to be "seated" by running the motor under light load for several minutes to conform to the commutator curvature. Check brush spring tension - springs should provide 1.5-3 lbs of pressure (weak springs cause poor contact and premature brush wear). Inspect the commutator for glazing, scoring, or uneven wear before installing new brushes.

For complete motor replacement with aftermarket units, the process involves removing the old motor from the gear assembly and installing the new unit. Most aftermarket suppliers provide motors with identical mounting patterns and shaft configurations to ensure direct replacement capability. Venture Manufacturing and similar suppliers typically offer motors rated from 200-400 watts with standard 12V DC operation to match original Power Gear specifications.g offers complete slide motor assemblies starting around $250, while Tuson RV Brakes provides both motors and complete gear assemblies.

When installing a replacement motor, follow manufacturer torque specifications and ensure proper electrical connections.l attention to the brake mechanism connection. Most slide motors incorporate electromagnetic or spring-set brakes that prevent unwanted slide movement. The brake typically requires both power and ground connections, and improper wiring can result in the slide moving unexpectedly or failing to hold position.

Test the rebuilt or replacement motor before final installation by connecting it to 12V power and observing rotation direction, speed, and current draw. A healthy motor should draw 15-25 amps under load and operate smoothly without excessive sparking at the brushes. Excessive sparking indicates poor brush seating, worn commutator, or internal winding problems.

For the mechanically adventurous considering a complete system retrofit, companies like RV Slide Out Motors LLC offer upgraded systems with better motors, improved gear ratios, and enhanced reliability. These systems typically cost $400-600 but provide significantly better performance and longevity compared to standard Lippert assemblies.

Professional Help Needed

While brush replacement and motor swapping are well within the capabilities of most DIY RV owners, certain situations warrant professional assistance. If your slide system shows signs of binding, unusual noises, or structural issues beyond simple motor weakness, have it evaluated by an RV service center or mobile technician before proceeding with motor work.

Professional diagnosis becomes essential if the slide mechanism itself has problems - bent rails, worn guide blocks, or damaged seals can cause excessive motor loading that will quickly destroy any replacement motor. Many RV service centers can perform slide alignment and mechanism inspection for $100-200, which is worthwhile before investing in motor repairs.

Electrical system integration may require professional help if your RV has complex slide controls, multiple slide coordination, or aftermarket slide control systems. Some newer RVs use CAN bus communication or other advanced control methods that require specialized knowledge for proper motor replacement integration.

For owners uncomfortable with electrical work or motor disassembly, many local electric motor repair shops can rebuild RV slide motors for $75-150 including new brushes, commutator resurfacing, and bearing replacement. This option provides professional results at a fraction of Lippert's replacement cost and often includes a warranty on the rebuild work.

Mobile RV technicians specializing in slide systems are another excellent option, particularly for owners who want the convenience of on-site service. These specialists typically carry common replacement motors and can complete the entire job in 2-3 hours. Search for "RV slide repair" or "mobile RV service" in your area - costs typically range from $300-500 including parts and labor for motor replacement.

Consider professional help if you discover additional issues during disassembly, such as damaged wiring harnesses, corroded connections, or problems with the slide's structural components. What starts as a simple motor issue can quickly become complex if underlying problems aren't addressed properly, and professional evaluation can save both time and money in these situations.