2004 Workhorse Chassis Ignition Problems...and then some

I had a viewer from Long Beach contact me about replacing his roof on a 2004 Winnebago Sightseer. We scheduled a time and location for him to drive from California to drop it off, but he was late..quite late. After calling him a few times, his motorhome showed up on a tow truck because the engine would not stay running. Surprisingly he was in very good spirits about the whole ordeal and gave me a walk-thru of all the custom changes he has made to it. It is obvious that he cares deeply about his Sightseer and I feel grateful he would trust my shop with it just from a couple KZbin videos. So before I can replace his roof, I have to get the motor home running. Here is a quick rundown of the ignition switch replacement.
Thanks!

[@ryanpollie3216]

After a three hour drive home, parked in front of my house. Went out to move it and key would not turn and could not shift out of park. Chassis is 2004 Workhorse P32 - Winnebago Sightseer. Problem was the ignition switch. Contacts had melted to the plastic housing, preventing movement of key and shifter. Replaces switch and all is good. Thanks to James for this video which got me on the right track to solving problem.

[@youtubechampion9377]

I had this issue on my 04 daybreak 8.1 gm chassis. The bus manufacturers have a tendency to overload the switch with all the extra features the coaches require. The proper repair is replacing the switch and putting a relay on the additional bus accessories so the switch triggers the relay but doesn't directly feed them. I was able to "wire" my bus to get us back on the road as I was stranded on the beginning of a long weekend in a small town with closed part stores.

[@kenwolfel783]

Thank you for this video! We were stranded at the fuel pumps at a Pilot gas station outside of Flagstaff AZ with a totally dead ignition switch and all dash light out! Between a few Winnebago users groups and your video we were able to figure out that the heater fan is tied into the ignition switch and over time will fry it!!! Your video was aimed at a roof issue but absolutely saved our lives when the first two mobile roadside mechanics and then the two Freightliner service techs were COMPLETELY clueless on where to start!!! The best part was when the parts manager had no idea where to look for the ignition switch and I was able to recite the part number from the NAPA box :-)>. We are now in Monument Valley and they waived ALL charges since I was able to diagnose and replace the switch myself!!!

[@AZExpert]

Wow. When I make a video it's mostly based on if I have time and something interesting. I never know if anyone will care, so it is very wonderful to hear that it was helpful. Thank you

[@microwavedsoda]

@@AZExpert your videos indeed make a difference . Fear of the unknown is huge too so after watching a few of your videos, that fear goes away. Not just because you solve issues, but that there are people like you out there that really care

[@niteninja0133]

@@AZExpert we all care about your videos

[@tomgalleo7709]

05 Itasca Sunova with failed Ignition switch presented as no lights on dash (LCD display & guages) & no audible tone when Key was turned. This happened while camping. Replaced part with US105 (KS6622 Napa) and full function resumed. Gratitude to James for helping us all dodge a financial hit of some significance.

[@AZExpert]

Happy it helped!

[@philw7174]

Interesting video, thanks James. Happy trails!

[@AZExpert]

Thanks for watching!

[@BJCulpepper]

I saw this video 2 years ago. Forgot to thank you for helping me. It was one of the most non-fun things I have ever done. lol

[@AZExpert]

LOL

[@RyanSmith-us8ol]

Thank you for this video I was able to find the same burnt switch that left me on the side of the road. New part from Napa will be here soon and the family and I can get off the side of the road.

[@AZExpert]

I hope you stay safe and this is the only issue. Good luck!

[@brianbiggs3484]

👍👍🇨🇦✌️🇨🇦✌️🔧🔧 Thanks James appreciate all your hard work & sharing the good and the bad 😊

[@jf4872]

The owner likely added more accessories which in turn adds more load to the ignition switch. I replaced the switch on my P-32 1994 Fleetwood Southwind Storm a few years back just as preventative maintenance (old one was working still). Bought an AC Delco one. Figured at that point it has provided 24 years of great service why wait till it fails while I'm on the road/freeway (Huge inconvenience). The switch failing was a common issue among that chassis series. Usually due to added accessories loading up the switch. A lot passes thru that switch.

[@AZExpert]

Thanks for watching! :)

[@rafaelgilabert5710]

You did a great job

[@AZExpert]

thank you!

[@byronewhite]

The item you call transmission lock link I found out was the head light dimmer switch.

[@byronewhite]

This was very helpful. In the process now replacing my switch. By the way what do you shoot your video with?

[@AZExpert]

You are welcome. I just use my cell phone. Samsung note 9 I think. Nice cameras and rigs fail too much for me lol.

[@RealCptHammonds]

Pardon my stupid question, but I'm looking to be prepared for this to happen to me. So here's my question: Am I correct in my assessment after watching this video that I can skip the disconnecting all those things on the left side of the column and just replace the part you showed on the right side of the column? Either way, I'm definitely going to be ordering that part to have on hand and am EXTREMELY thankful to you for all your excellent videos that has kept who knows how many coaches from ending up in scrap yards, which would have obviously broken wallets and hearts. You're a good man and I pray for your continued success.

[@bounderchris]

That is crazy that in 2004 they would still use that old column… must be a Winnebago thing with their ebrake because Fleetwood doesn’t use that old column…. And their ebrake is manual… unless that’s not a w but a p30 chassis?

[@liannebennett5264]

If my 2002 motorhome with 8.1 workhorse (15,000 miles on the odometer) starts up first try sometimes and takes up to four attempts other times, would that indicate the beginnings of a failure of this switch?

[@TheIndyDon]

The rod to my ignition switch goes through the floor and I haven't found the other end yet. 2004 workhorse w22 with tilt wheel. Any ideas?

[@docyt]

I had this same problem in 2015 on a 2015 Damon with the same chassis. Was stuck in SD for a few days while they fixed it based on the TSA that Ike brought up down below.

[@AZExpert]

Thanks for sharing. I wasn't aware it was a large issue.

[@docyt]

Doing 65 down the interstate and all electric went out on my 11 ton RV including the power steering. That was no fun getting to the side of the road ;)

[@hitthatdude21]

I had this same exact problem it's all fixed now however my brake lights dont work not in my 2004, the turn signals and flashers woke and the middle brake light but not left and right ?

[@AZExpert]

I think workhorse has them on separate fuses under the hood

[@franklinwall3126]

I can't se to get power to the dash on my 03 infinity 35t 8.1l vortex rv. Power to starter can cross oner but no power to ignition... Any ideas?

[@AZExpert]

i'd check if there is a chassis battery disconnect that is off or broken

[@U72740]

Hello. Thanks for this video. I have a question for you. Is this motorhome mounted on a P32 chassis with an 8.1 liter chevrolet engine? Because I have the same problem with my motorhome. I'm having trouble finding the part for the repair and I want to be sure I'm buying the right part (oddly Napa is having trouble finding a substitute for Workhorse parts) and I don't want to buy Workhorse parts because it they are much too expensive, it borders on fraud. The motor of my motorhome does its job very well but the chassis is a real nightmare, the parking brake system is really strange as well as poorly designed. I hate the Workhorse company, never again .... over my death body. Thank you from Canada PS : Sorry for my english it's not my mother tongue

[@13yearsaprepperr.jtilbury.51]

man change the battery in the smoke alarm ,, that chirp ia a PITA

[@AZExpert]

Yes, I have become deaf to that sound as it is so common in RVs but I really needed to get the motorhome off the drive after the tow truck dropped it off. I think I replaced the detector later. Thanks!

[@13yearsaprepperr.jtilbury.51]

@@AZExpert happy new year brother ,,,, have a great day

[@carlbeaver7112]

GM ignition switches have been weak for decades. They famously overload their electrical, especially on P series. I had a MAC Tools truck that, at night, would smell of something getting hot. I found they had 37 (!) exterior lights attached to ONE 18 ga. wire from the headlamp switch. Guess where the smell was coming from. *rolls eyes* There is also a TSB on GM & WH re: the switch overheating and an available add-on relay kit to prevent further problems. They have too much current pulling through that pin. The kit mounts a relay next to the forward fuse block (underhood), it's pretty simple and a knowledgeable person could figure it out without the kit. The kit does make it a tad easier, having the terminals, etc. provided. Here's the kit, it's pricy for what it is ($6 relay and some wiring.) If you do a little digging online you can find a number of pages describing the do-it-yourself instructions. www.workhorseparts.com/W8002060-Ignition-Protection-Kit Instructions: www.nwtfc.com/wp-content/uploads/2020/04/Workhorse-Ignition-Relay-Instructions.pdf And there is an updated, HD Ignition Switch available: W8002086 (it's green, in case yours may have been updated) If the ignition switch connector looks rough I'd replace it as well. Most part stores will have a replacement available (because it's a common problem.)

[@AZExpert]

Hey thanks for the tip!

[@carlbeaver7112]

Just looked to see what was powered on this circuit in my '04 HR Traveler ('03 P32): ABS Relay, A/C Relay, Purge Solenoid, MAF Sensor, L & R O2 Sensors, Electronic Throttle Module, Fuel Pump Relay, PCM / TCM, ALL Coils, ALL Injectors, S Terminal - Alternator. Oh, and the Starter Solenoid (through the P/N Switch), if you actually want it to crank over. Some of those are kinda necessary things, unless you just wanna sit in your driveway making engine noises. I suppose the other way would be to turn on the ignition switch and count to ten before cranking the starter? /s