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Old 11-10-2006, 06:38 AM   #1
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Is anyone else having issues with water getting into air intake or black box? What about water getting into wiring of wipers causeing them to stay on in off position, not work or only work in high speed? I've had my unit back to dealership and back to Newmar in Indiana 7 times for the same 2 issues. Newmar is saying it's a Workhorse issue and Workhorse is saying its a Newmar issue. Bottom line the unit can not be driven in rain.
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Old 11-10-2006, 06:38 AM   #2
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Is anyone else having issues with water getting into air intake or black box? What about water getting into wiring of wipers causeing them to stay on in off position, not work or only work in high speed? I've had my unit back to dealership and back to Newmar in Indiana 7 times for the same 2 issues. Newmar is saying it's a Workhorse issue and Workhorse is saying its a Newmar issue. Bottom line the unit can not be driven in rain.
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Old 11-10-2006, 08:34 AM   #3
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jkhcincy, welcome to irv2
Yes there has been problems with water in air intake sys. A simple fix is to place a weather strip accross the upper crack of your hood opening. If you will go to "FIND" just above you and type in WATER AIR INTAKE, take off check mark, you will find 183 posts some with pics, on this subject going back to 2004 when I post this same question on many forums. Go to second page 'NEWBIES water problems with PICS" pg #2 or read thru whole thread for added info.
Its a Newmar issue because of the hood opening. Other MFG's have same issue not just Newmar.
The fix will take care of both wippers and the TUBA intake. You have 03 coach later models had problems will filter box takeing in water around the box seams that had to be sealed.
Newmar and WH had fixs that may work but most that didn't.
Come down to the Newmar forum and I will welcome you and make you a member of forum.
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Old 11-10-2006, 11:30 AM   #4
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Thanks for the insite but this fix was already tried by Newmar. I had MH at dealership 6 times for these issues and finally took MH up to Newmar to fix. They put weather stripping on, re-routed wiper wires, and placed covers inside wheel wells to prevent water from getting in. Did not work. Unit is back at local Cummins workshop and Workhorse specialist is going to be looking at it.
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Old 11-10-2006, 01:15 PM   #5
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That is to bad its worked for many people with the problem. I still have it to protect the wippers but I have taken out the TUBA and installed a new CAI that allows more air thru radiator. If you looked at pictures you can see it in lower left hand corner. Good luck with finding your problem just make sure your filter box is sealed the covers inside wheel well will not stop water into box.
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Old 11-28-2006, 08:51 AM   #6
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I have a 2005 Newmar Kountry Star with the same issues as you. I have sought a solution for the past 14 months.

I sealed the hood opening with a gasket. I placed Plexiglas sheeting in the engine compartment to prevent water intrusion near the air intake. I finally got a 3 ft. piece of
flexible aluminum heating duct at a Lowes store. I cut off the "tuba" intake opening, installed the aluminum ducting onto the "tuba" intake, then installed the Tuba's opening I had cut into the open end of the flexible tube. This I positioned high and to the passenger side of the compartment. It is held in place by plastic straps. I also covered that tubing with a foil sandwich of insulation (also from Lowes)to prevent any water getting in through the seams and help reduce any heat build up plus dampen any vibration noise that might occur.
As to the wiper issue, I covered the ground contact with a silicone seal and taped the plastic electrical wiper connector to prevent water from getting into the contacts. You need to wrap not just the connector, as I initially did, but also the wires for at least 6 inches to each side of the connector to prevent water from running down the twisted wires and into the connector. It is water inside this connector that causes the problem. Now my wipers operate properly.

As to the ability to run in the rain, all that I have done did not resolved the issue.
My coach is currently at Stout's RV in Greenwood Indiana, and I believe they have found the problem...and the cure. They did not sell me the coach, but they are both an RV dealer and a workhorse service center. They understand that operating in the rain is a necessity, not an option.
While my selling dealer was of little help except to install a replacement air filter that fit better than the original, the Workhorse organization and several visits to different Workhorse service centers have been totally useless. Phone calls, emails and letters to workhorse have gone unanswered or gotten a boilerplate/form letter reply, and of course Workhorse has denied responsibility. It is really disgusting when a manufacturer has a problem but is unwilling to admit it or help find a solution. Listening to the RV industry manufacturers, it would seem the problem is a "one of a kind" or somehow the owners fault and therefore the owners responsibility to fix.

The cure: a technician at Stouts found my filter air box must have been improperly installed. There is a crimp in the air intake tube at the front of box along the top of the assembly. This allows water a place to get sucked in directly against the air filter and eventually saturate the filter to the point the engine bogs down. I was always suspicious of the air box, but could never pinpoint the problem. Having relocated the air intake, the problem had to be at or near the air box. The mechanic took a digital photo of the defect, and the folks at Stouts told Workhorse the entire system needs to be replaced. Workhorse agreed.

That would seem a simple thing to do. However last week, the first air box assembly Workhorse sent to Stouts was the wrong one and they are currently waiting for Workhorse to ship the correct one. You would think the chassis manufacturer would have specs and manufacturing records to be able to ship the correct part for a chassis they built!!
I am encouraged that the people at Stouts found the defect and probable cause of the water issue when everyone else has failed, (even I did not see it!). I may not know for a while if the new air box is the final cure, but hope springs eternal.
In the meanwhile I remain disgusted with the finger pointing and denial of any responsibility by coach and chassis manufacturers as well as the failure of my selling dealer to actively aid my search for a solution. They all made money off my purchase, but then want to deny any further responsibility for the problem.

I hope this information is helpful to you and that you can get a better response and quicker resolution to the problem. Motor homes should not be just sunny day vehicles!
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Old 11-28-2006, 10:13 AM   #7
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Good post Richard hope it solves your problem.
After I placed the weather strip it solved all my problems and I let people know about it. Well it didn't solve their problem as it turned out it filter box had its own problem on newer coaches with water getting by the seams of the box. Some people found a paper filter that had a thicker rubber gasket around paper filter that solved their problem.
Last summer I have removed all of the air intake system provided by WH and installed a CAI sys from BRAZELS with good results.
I still have the weather strip to take care of the other half of the problem the messed up wipers.
I would take your coach out in a good thunder storm and give it a test if engine starts to spudder pull off road till rain stops than you should be able to move on.
Check out the Workhorse forum and you will see pics and info on the new CAI I have installed.
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