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2007 Intrigue- Plate modification

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Plate that needs holes for proper venting
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HWH slide hoses that get hot, swell, and leak

Author "Lee" owns a 2007-40' Intrigue: 

The HWH Hydraulic System that manages the extension/retraction of the slides on our motorhome was working perfectly until it failed on in March 2009 while traveling. Advice from calls to HWH and others guided us to the system AFT fluid reservoir in the front electrical bay and also to the sync cylinder for the system, which is located in the upper rear corner of the tag axle wheel well (curb side). We found the AFT fluid reservoir to be empty (loss of 5 quarts). A protective metal plate covered the sync cylinder but it was clear the source of the leak and problem was underneath the protective metal plate - AFT fluid stains were evident all around the lower edges of the metal plate, around parts of the wheel well and along the lower edges of the coach fiberglass body (see pictures).

At home I removed the metal plate cover and found the sync cylinder.

The main hydraulic line from the AFT reservoir had separated from the sync cylinder, resulting in a rapid loss of fluid (see pictures). It is evident the metal plate cover was a standard fabrication by CC to shield the sync cylinder from road debris. The plate is cut and bent to size, is 13" X 29" and made of 1/16" sheet steel, covered with a tough black undercoat substance. While the space under the metal plate is open at one side, apparently that opening does not provide sufficient ventilation to avoid excessive heat build-up as HWH, Branson Motorcoach, and CC technicians I have talked with all agree that excessive heat build-up caused the line/cylinder separation.

If you haven't had the failure yet I'd recommend you remove the plate, drill a number of holes in it for ventilation (see pictures) and remount it. The plate may already have some holes so you may decide to do nothing if you think they are sufficient.

Use the HWH leveling to raise the coach. Block the frame at the rear for safety. You will be able to reach in over the tag tire and use a socket wrench to remove the 8 sheet metal screws. The 2 innermost screws (top/bottom) are very hard to reach. You need long arms or a friend with long arms. The plate weights a few pounds so remove one of the close upper screws last and be ready to grab. There is no one right vent hole configuration. I did a number of 1/2 and 3/8 inch holes on a 2 inch grid I marked on the plate. Respray the cut metal with rust inhibitor paint. Remount.

While traveling, visually check the bottom of the plate for evidence of AFT fluid before moving the slides out (see pictures).

If you were to have a failure, have your repair shop install a hose from Parker Hannifin, not HWH - a better product

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Lee
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