Banks Exhaust problem

[03Dolphinlx]

I have a 2003 W-22 chassi (27k miles) with a banks exhaust system. On a recent outing I got a "Check engine" lignt on the dash. I took my RV to a local repair shop soon after. The mechanic told me that the banks headers melted my Knocks sensor on the passenger side (Just above the starter motor). My starter and all the starter wires have been shielded but not the knocks sensor. I have since replaced both the sensor and the melter plug. Sensor $65 and plug pigtail $20. Has anyone else experienced this?? If not you need to check to see if it could happen to yours. I have since wraped the sensor to protect it from happening again.

[JCM]

No problem in 2 years but I will crawl under and have a look.
Yhanks for the suggestion.

[TXiceman]

I doubt if the headers caused a melt down of the sensor. If the wiring is right and secured, it should not be a problem. Just a convient excuse. We ran the banks headers on our 99 E450 class C and never any problems.

Ken

[DriVer]

Quote:

Originally Posted by TXiceman I doubt if the headers caused a melt down of the sensor.

Ken, {FYI} Our sponsor Brazel's has reported some anomalies in this area when incompetent installers fail do do the install correctly.

[03Dolphinlx]

The banks headers come within 1 1/2 inches of the knocks sensor on the starter side. If it isn't insulated or shielded the heat will eventually melt the factory pigtail and plastic on the top of the sensor.

[skipsor]

I looked at my '04 W20 Winnebago with the Banks system installed and lo and behold, the same sensor plug that DolphinLX wrote about is also melted on my MH. Along with the melted plug I also noticed that the battery cable insulation, the large red cable that's out of focus in the second photo, has also started to melt and the crossover pipe between the left and right exhaust pipes is cracked on both ends. I am the original owner of the MH and I also had the Banks system installed by Banks at their shop back in January 2005. The rig has 38,000 miles on it and probably 33,000 on the Banks.

The melted plug is located on the right side of the motor just forward of the starter motor. There doesn't appear to have ever been a heatshield installed there but, interestingly enough, on the left side of the motor, in approximately the same location, there is a heatshield in place and the connector looks brand new. Curious why they put only one shield on.

If anyone has the Banks system installed on their MH you may want to go underneath it and see if you have either of these problems.

Cracked pipe1.jpg

Melted plug & batt. cable1.jpg

L:side sensor with heat shield.jpg

[JCM]

I have had the same cracks. When I contacted Banks, they said that they had some problems with their welds. I went to a local muffler shop and they had it re welded in 5 minutes. I will crawl under the coach and look at the sensors.

[03Dolphinlx]

I had the same cracks about 2 years ago and was told the same by Banks. This year I had a 15" crack in a pipe seam that I mig welded myself. I called banks and they said it was just a poor MFG weld.

[Jeff H]

I creeped under our 06 Dolphin last week after my wife showed me the pictures. Crossover pipe is good. The 2 small shields were indeed cracked. I was able to repair them.
Then, this last Sat. we met the OP up at the Rincon! We had lots of tips and fixes to share and had a very nice time with them. The weather was pretty darned good too!
Hope to see you both soon,
JC and Carm