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Old 10-17-2016, 03:29 PM   #1
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Join Date: Nov 2011
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Onan generator removal

Onan generator 7.5 model HDKAJ11451H serial # C040614436 in 05 Expedition

I know this old problem has been dealt with way back and I have read the responses but it is new to me so with all of your patience could I get a little reassurance. Generator runs just fine but recently when I hit the star switch it immediately tries to start at any temperature, without waiting for the glow plugs to activate. A couple of times, several years ago it would shut down after 5 minutes but then Ive never had it happen since. I suspect from the previous posts the problem with start up will be the temp switch for which the gen will have to be removed. With 875 hrs on the unit it should probably have the belt, thermostat, cap and anything else recommended. I want to remove the unit, outdoors , BC Canada, and do the repairs or roll it into the small shop. Not much room to work under neath so I was considering dropping the whole front of the MH, only 14 bolts, and slide it out on supports so I can remove the top cover.

Does this sound OK or would there be a better procedure. Don't suppose there would be another cause for the hard starts so the removal would not be necessary, although since the maintenance probably hasn't been that great on the gen, it is probably as well to give it a going over.

Would appreciate any thoughts or suggestions. Away back in 2014 or so there were a few posts on this problem from a couple of members who seemed to have a good handle on it and one, I believe, even had some pictures.

Thanks in advance
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Old 10-17-2016, 05:10 PM   #2
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I used a transmission jack from Harbor Freight to remove from my old Winnebago DP. Raised the front of the coach and lowered with the jack. It wasn't easy, but a whole lot better than removing the front cap.

I will never again own a coach that doesn't have a generator slide.
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Old 10-17-2016, 05:23 PM   #3
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Before you expell too much energy on removal, try locating the connector on the umbilical cord from the generator to dash control. Pull the plug apart and give it a good spray with some contact cleaner, assemble with some dielectric grease. My 7.5 was giving me all sorts of starting issues so in desperation I tried cleaning this connection. Not a problem in three years since.

Don't want to slow a good man down but I'm kinda lazy and always look for the easy way out. . Sometimes it works..
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removal, generator, onan

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