We love RV life. There’s something so intimate and rustic about living in a crazy, small rolling box, and there’s something so exciting about discovering new places and meeting new people. Those things just don’t happen in the same way or with the same frequency when we stay home!

But there’s another side to RV life that eventually hits every RVer: unexpected breakdowns and repairs. Ugh!

Ahem… Breakdowns and repairs!

Of course, conventional sticks-and-bricks lifestyles often involve unexpected breakdowns and repairs too. But in an RV these things usually happen in a place where you don’t know anyone and somtimes happen in a place where there’s no one around!

When your sole means of transportation (and housing) isn’t functioning, your travel plans get totally upended, and it’s easy to feel vulnerable.

2015 – The Year of The Breakdown!

For most of our years of full-time RV travel, our equipment failures were spaced out enough so we could tackle each one without being overwhelmed. Back in 2015, however, we had a series of major RV breakdowns on a two month trip from Nova Scotia to Arizona.

Our fifth wheel’s roof sprang a leak during the endless torrential rains in Nova Scotia. Our living room rug was completely soaked! We bent an axle on a potholed back road in Nova Scotia. Our RV refrigerator died in Kentucky. Then our fresh water tank cracked and our RV toilet quit working. And the trailer suspension failed completely as we arrived Arizona.

What an insane cross-country trip that was!

Yet, as with all of life’s ups and downs, what’s most important is never the problems themselves. What matters is how you react to them.

The things that stand out in our memories from that trip in 2015 aren’t the breakdowns. Actually, I had to re-read my logs to remember all the things that went wrong because those memories have faded. Instead, what we remember most from that span of time were our great travel adventures.

We loved the quaint charm of Lunenburg and Peggy’s Cove in Nova Scotia, and we were smitten by the coastal beauty of far Downeast Maine. We’ll always remember the incredible kindness of the RV service shop manager in Bangor where our trailer axle was replaced and our ride on the Cog Railway in New Hampshire. We were heartened by the incredibly warm community in Maysville, Kentucky, where we were treated like long lost family for our entire three week stay. When our RV refrigerator died shortly after leaving Kentucky, we had a blast barbecuing all our frozen meat in a Camping World parking lot and sharing it with the mechanics who’d replaced our fridge.

Those kinds of experiences are why we get such a kick out of RV travel, and if we can get through the breakdowns and repairs unscathed, all the better.

Downeast Maine – Despite all the breakdowns, 2015 was one of our best RV travel years!!

Fast forward to 2023

This summer we were on a Rocky Mountain high for over 10 weeks. But in between our sunset strolls on the beach, hikes alongside gurgling streams and gorgeous wildflowers in the snowcapped mountains, we had one breakdown after another. Mark’s To Do list of repairs grew longer with time, not shorter, as he struggled to keep up.

It was a real challenge at times to keep our spirits up. But then we’d see a stunning sunset or the play of light and shadow on the mountains, and we’d remember why we were out roaming around in our RV, even if our equipment was falling apart.

In the end, though, we cut our summer season short by about 3-4 weeks when our bathroom skylight sprang a leak on a bitterly cold and sopping wet night on a mountaintop. By then, our furnace was broken, the roof was leaking and we could no longer unhitch the truck (details below).

In our full-time RV lifestyle, we would have sought out a comfortable location where we could tackle these repairs one by one. We would have stopped sightseeing and kicked back until we were caught up! In that lifestyle, losing a month or two of sightseeing is no big deal because there are always unlimited sightseeing opportunities ahead.

However, in our seasonal RV travels, we not only have the option to go home at any time, but we know that home is the final destination. Each day of travel is more precious than if we were full-timing because the number of days is finite, and we hate to waste any time with a breakdown.

Buddy was loving every minute of our travels and was oblivious to our equipment failures.

Likewise, if an RV breakdown grounds us in one spot for a long time until it’s fixed, we’d much rather be living in the comfort of our own home and dealing with the repair there than be out in some remote location with few resources.

Those are some of the subtle differences between seasonal RVing and full-time RVing: The ability to run home vs. making the best of being “home” already; the pressure to make the most of each day in the trip vs. letting life’s storms blow over and resuming our travels afterwards.

So, we had an interesting pairing of truly beautiful destinations and travel adventures this summer alongside some very frustrating breakdowns and repairs.

Here’s a recap:

Mark checks the engine once again…

TRUCK BREAKDOWN

Our big beautiful 2016 Dodge Ram 3500 dually truck began throwing error codes towing our trailer up Monarch Pass. This is a beast of a mountain pass that our truck would ordinarily shrug off as no big deal.

However, as we climbed this pass, the Check Engine light came on three times accompanied by several error codes related to the throttle position sensor and the turbo actuator. The truck went into Limp Mode each time, unable to maintain the speed of traffic.

.

We had to pull over and turn the truck off to clear the codes so we could drive at the normal speed of traffic for a few more miles. Then the Check Engine light would come on again and we’d repeated the whole process. Fortunately, there are lots of pullouts on the Monarch pass ascent where disabled vehicles like ours can seek refuge!

Once over the pass, we continued on to Buena Vista and found a safe place to park about 200 yards off the highway outside of town. The truck didn’t throw any codes until we pulled off the highway. Luckily, our jaunt down a lumpy US Forest Service road was short. Although we didn’t know it when set up camp, that spot would become our home for the next three weeks!

As we set up camp, a storm was brewing…in more ways than one.

It turned out the truck had three separate problems. Why they all hit at once, we’ll never know.

Throttle Position Sensor

The first failure was the Throttle Position Sensor which is part of the accelerator pedal. We found a local diesel mechanic who replaced it within a week (we had to wait for the part to arrive) and the error code never came back.

Exhaust Manifold and Turbo Failures

The other two problems were inextricably linked: the exhaust manifold and the turbocharger. We spent a lot of time learning about these parts, why they tend to fail, and what it takes to replace them. Yikes! If one or both of these fail, you’ve got a huge and expensive repair on your hands.

Two of the bolt studs at either end of the exhaust manifold had completely sheered off! Why? The exhaust manifold repeatedly expands and contracts from heating and cooling. Ultimately, this expansion/contraction caused the exhaust manifold to warp, and that bent and eventually broke the studs.

We discovered this is actually a fairly common problem! It can happen at any time. Sometimes it occurs in the first few thousand miles under warranty, sometimes at 85,000 miles like our truck was, and sometimes at 150 thousand miles or more.

The Ram exhaust manifold is a single piece of steel, and the heat in that area is extremely high. To avoid warping, several after market exhaust manifolds are made in two pieces that fit into one another like a sleeve. This allows for expansion and contraction without stress as the surrounding temperature changes, and prevents the bolt studs from breaking.

The signature symptom of a failing exhaust manifold is both the smell of diesel fumes in the cab of the truck and a high pitched whine caused by air leaks when the engine is running.

As we learned all this, we realized that our old 2007 Dodge Ram 3500 probably had loose or broken bolts on the exhaust manifold as well. We had thought the occasional smell of diesel exhaust in that truck cab was due to the engine going into a Regen, but it was probably exhaust leaking from the exhaust manifold.

Exhaust gas blowing through the engine is not good for it. So, our companion gear failure was the engine turbocharger which had become totally gunked up from filthy exhaust air blowing through it. There was black, sticky, gooey stuff all over the turbo fins. Unfortunately, we had to replace turbocharger.

Ironically, one afternoon a Ford diesel truck towing a large utility trailer came flying into the area we were camping. White smoke billowed out the tailpipe. We chatted with the driver and his companions as they waited for a tow truck from their shop in Kansas to come and tow them home. They were certain their truck’s turbocharger had failed too.

The stringent emissions requirements on diesel engines make the turbochargers on all pickup brands susceptible to failure because exhaust fumes flow through them rather than fresh air.

Our biggest dilemma was deciding where to have the work done. We were in the heart of the Rockies which is full of small mountain towns and high elevation mountain passes. We spent several days talking to diesel mechanics with top Google and Yelp ratings from as far away as Grand Junction, Denver, Colorado Springs and Cheyenne, Wyoming.

Labor prices ranged from $120/hour to $200/hour. Mandatory diagnostic fees ranged from $85 to $450. Prices of parts ranged from the prices we saw advertised online to twice the prices found online. Getting scheduled for the repair ranged from next week to two months from now. Solutions ranged from “We use only Dodge (Mopar) OEM parts” to “We prefer the after market brands BD Diesel, Cheetah and ATF.”

Needless to say, it was dizzying interviewing these mechanics and narrowing down which one would be a good fit.

There are gondola rides at Monarch Pass. Next time!

The trickiest thing was that in order to drive our truck to a mechanic, we faced a towering mountain pass in every direction: Monarch Pass, Hoosier Pass, Cottonwood Pass and Kenosha Pass all lay between us and the diesel mechanics we talked to. We were concerned the truck wouldn’t make it towing the trailer. If the truck died en route, we’d have a huge towing bill on top of the repair bill!

In the end, we hired the local diesel mechanic who had replaced the throttle position sensor. He was a highly rated one man operation and was good hearted and knowledgeable but swamped. He stopped answering his phone or responding to messages during the weeks we worked with him. It was a dark time for us as we wondered what was going on and whether he could do the job. However, he got it done.

In the end, the parts and labor for all the truck repairs came to $6,000. Ouch!!

Time for a Vacation!

In the interim, the truck was okay to drive if it wasn’t towing the trailer. So, to improve our spirits and put our minds back on the right track after 10 days of waiting for the throttle position sensor repair and doing a deep dive into exhaust manifolds and turbos, we left the trailer in its boondocking spot and went on a two night mini vacation to the town of Frisco!

Upon arrival in town the first morning, we treated ourselves to a delightful breakfast out. Eggs Benedict and pancakes served at a sunny outdoor cafe under bright yellow umbrellas on the edge of a quaint street was just what the doctor ordered. Our good spirits were instantly restored.

A tasty breakfast on a flower-filled patio far from our RV troubles put us in great spirits.

We strolled the town, checked out the campgrounds, walked the shores of pretty Dillon Reservoir and took part in Frisco’s weekly outdoor music festival one evening. What fun!

By the time we got back to the trailer, the parts had arrived and we were totally refreshed and ready to deal with the awkward logistics of the truck, trailer and repair. Luckily, the repair took just one very long day that kept the mechanic in his shop until well after dark.

TRAILER EQUIPMENT FAILURES

Furnace

We’ve used our RV furnace many times since we bought the trailer in 2022, but it suddenly quit working after a few weeks in Colorado. Of course, this was on a very cold morning when we really needed it!

The gas flame would light and the blower would blow, but then the flame would go out. Sometimes it would stay lit for 3 seconds before going out. Sometimes it would last for a few minutes. But it never stayed on long enough to warm up the trailer. It just cycled on and off repeatedly.

Hmmm….so what part of this RV furnace is broken??

Mark troubleshot it in depth, tearing the whole furnace apart. The orifice that might have been clogged was totally clear. The sail switch was also working perfectly. We concluded that it needed a new motherboard (a few hundred dollars). We just lived without the furnace for the rest of the summer even though we wished we could use it on many cold mornings.

Ironically, now that we’re home and it’s 95 degrees in the afternoons, the furnace is working like a charm. It might have been the altitude. We’ll see how it goes during our upcoming winter camping trips.

Landing Legs

When we arrived in Lake Granby and started to unhitch, the clutch on the trailer’s landing legs started slipping as we extended them to raise the front of the trailer. We were barely able to raise it enough to get the truck out. So, after we hitched up to leave, we decided not to unhitch again until we got home. Fortunately, the RZR was able to get us where we needed to go in the interim.

Mark had to replace the landing legs on our Hitchhiker fifth wheel many years ago, and he did it while boondocking in the Arizona desert. He was prepared to do it again, but now that we’re home, just like the finicky furnace, the landing legs seem okay!

So we’re waiting to see if it happens again. Replacement landing legs are about $700-$800.

Skylight Leak

On one of the last nights of our trip, we were camping at about 9,500’ in a remote part of northern Colorado when a massive rain storm blew in. After a few hours, we heard “drip-drip-drip” in the shower and discovered the bathroom skylight had sprung a leak. Fortunately, it was dripping into the shower, so the puddle of water was contained! However, that equipment failure was the final straw that sent us packing for home.

Quitting early didn’t end our fun summer travel adventures, though. On our way home, we had lots of good times in Utah that we’ll share with you.

After we got home, Mark was able to fix the leak using Flex Seal Liquid. 24 hours later, a huge overnight rainstorm came through and proved to us that his repair is good! Yay!

POLARIS RZR SIDE-BY-SIDE BREAKDOWN & FAILURES

Our Polaris RZR had always been very reliable but this year it had several failures.

Overheating

First, it overheated at the top of a mountain near Rico near the beginning of our trip. We were several miles from our campsite! Mark is a quick thinker, though, and he put it in neutral and we coasted for 3 miles all the way down the mountain!

Even our trusty RZR acted up on this trip!

At the bottom, the engine had cooled enough for him to start it up again and drive us the final mile back to our campsite. He topped off the anti-freeze that had steamed off, and the engine temps have been fine ever since. We think it was caused either by the high altitude (10,500’) and/or by inadvertently climbing the mountain at slower speeds in high gear.

Ignition Switch

One day, Mark tried to start the RZR and it wouldn’t start. When he turned the ignition switch off, the start motor kept running! He had to disconnect the battery cable to get it to turn it off. He removed the ignition switch and lubed it with WD-40. Then he put the key in the ignition (with the battery disconnected) and worked it back and forth in the On and Off positions repeatedly. This fixed it. However, just to be on the safe side, he then installed a new ignition switch.

Battery corrosion

When we were having our problems with the ignition switch, the RZR started having trouble with cold starts. The engine would turn over but it wouldn’t stay running when it was cold in the morning. Checking things out, Mark discovered the terminals on the brand new battery he’d just installed were extremely corroded. That might have explained why it wouldn’t stay running. The corrosion was odd, however, because the old original factory installed battery he’d replaced after five years had had clean terminals!

We talked to several Polaris service shops in our travels and they said it was either inferior lead in the battery (an AGM battery from O’Reilly’s) or a loose battery connection.

Mark cleaned the connections with a battery terminal wire brush. The connections seemed tight. However, they were so corroded he decided to cut the terminals off the battery cables and replace them. He protected the new terminals from future corrosion with CRC spray. He has checked the battery frequently since then, and there is no corrosion.

MAIL FORWARDING => LOST POSTAL MAIL

When we set up our mail forwarding for the summer, USPS left off the mailbox number (PMB) when they entered our forwarding address on their computers! This meant the company receiving our forwarded mail, Americas Mailbox, had to look up our mailbox number manually for each piece of mail that arrived.

We discovered that Americas Mailbox doesn’t look up PMB numbers during the busy summer season, though. Instead, they return those pieces of mail to the sender.

Our local postmaster tried to enter our PMB number on our mail forwarding address on the USPS computers, but to no avail. Only two pieces of mail came through with a USPS mail forwarding sticker that included our PMB number.

A few pieces of mail came through with a hand written PMB number because some kind soul at Americas Mailbox took the time to look it up.

We never received at least 80% our mail. Many companies who got the returned mail then assumed our home address was invalid. So, we’ve had to reassure them that our home address is still correct. What a mess!

How did this screw-up happen? On the USPS mail forwarding form, there is a box where you enter your PMB or Apartment number. In the future, we will put the PMB number on the same line as the street address rather than putting it in that box!

On the bright side, we found out that the website Americas Mailbox uses for customers to see their mail and request it to be forwarded to them, ipostal.com, actually offers a mail forwarding service directly.

This is great for seasonal RVers because you can choose an address that is near your home. That way, your mail doesn’t have to travel cross-country to a far distant mail forwarding company. Also, you’ll see your incoming mail within a day or two rather than a week later.

You can buy just a single month or two months of mail forwarding. Even better, because they don’t offer vehicle registration and other services, iPostal’s fees are much cheaper than full service companies like Americas Mailbox. However, iPostal is not an ideal option for full-timers who need those additional services.

INTERNET ACCESS PROBLEMS

For most of our full-time RVing lives and for last summer’s RV adventure we used a Verizon MiFi Jetpack 8800 hotspot for internet access. Before we left this year, we used it for a few months at home and all was well.

However, when we got to Colorado it didn’t work in the small mountain towns between Cortez and Gunnison, including Rico, the outskirts of Telluride, the Blue Mesa Reservoir and Silver Thread Scenic Byway to Creede and South Fork. We went for 17 days without internet access in the rig.

Talking with the locals, we discovered most Coloradans in that area use AT&T. Interestingly, when we’d camped near Dubois, Wyoming, last summer, a fellow RVer with an AT&T hotspot was getting an adequate signal while our Verizon hotspot had no service at all.

Up the creek…but at least he’s got a paddle!

So, when we got to Gunnison, we picked up an AT&T 5G hotspot. We had internet access for the rest of our trip. The AT&T 5G hotspot was generally faster than the Verizon 4G hotspot. In many places we had good service via AT&T and nothing via Verizon.

However, the AT&T hotspot is a Franklin A50 model, and it has a very flaky battery and even flakier charger. We’ve had trouble turning the hotspot on and off, and the charger failed completely. Luckily, the Verizon charger works on the AT&T hotspot. However, it was frustrating to buy a hotspot that had so many problems.

More distressing, though, was when AT&T charged us a day ahead of time for our prepaid month of service and promptly shut down our service because “we had no data left!” WTH??!!

This happened first thing on a Saturday morning. I called AT&T and discovered — to my horrified astonishment — that they provide support only on weekdays!!

We’ve thought about Starlink and have friends who have it and love it in the places where they’ve traveled so far in Arizona. However, at $600 for the equipment, it’s a pricey piece of gear. It’s big and ungainly for quickie overnights in pullouts and rest areas, and it doesn’t work while you’re moving. Their service continues to evolve, though, so we’ll keep an eye on their offerings.

We’ve never had multiple hotspots before, but we liked the ability to choose one or the other. Now that we’re home, we’ve been surprised that the Verizon 4G hotspot is consistently far faster than the AT&T 5G hotspot, even with 5 bars of 5G.

Hotspot speed depends entirely on where the tower is in relation to where you are, whether it is equipped for 4G or 5G, whether your hotspot can receive 4G or 5G, and how busy the tower is for that provider.

Bottom line, we could have avoided those 17 days of being incommunicado if we’d had an AT&T hotspot at the time. But we were many miles from an AT&T retailer. Fortunately, the store in Gunnison was able to order one for us when we got there.

The Verizon store in the same strip mall told us they didn’t sell hotspots and couldn’t order one. We’d been mildly interested in upgrading to a Verizon 5G hotspot because there were rumors a tower near where we’d been camping had Verizon 5G but not 4G. If 4G equipment is being removed when 5G gear is installed, it would explain why our 4G hotspot has been increasingly unable to connect in places were we used get one bar of usable service.

FINAL THOUGHTS

All in all, despite that very long list of equipment failures and unexpected expenses, we had a truly blissful summer. We got to see many parts of Colorado we’ve never visited before, and they were all beautiful. We also got into Utah’s red rocks a little bit at the end.

Traveling in any form always involves risks, hiccups and unexpected frustrations. But in reality, all of life is that way. It’s just that when you’re on the road, you feel more vulnerable.

When storms gather in the RV life, it’s only natural to feel vulnerable.

For every moment of emotional (and physical) discomfort when things go wrong in the RV life, there’s another moment of sheer joy when you witness something extraordinarily gorgeous that you would never see in your own backyard. Or you meet a new friend you would never have met otherwise. Or you visit a destination you’ve always dreamed of seeing.

Hotel or AirBnB travel is another way to go, of course, and we often joke that we’ll sell it all, buy a sports car, pack a few bags and go traveling that way. But we like having the comforts of our own rolling home with us. So, we have to accept that unexpected breakdowns and repairs are an integral a part of RV life. And in reality, that snazzy sports car could leave us stranded too!

Now that we’re home, we’ve cleaned the rig thoroughly and Mark has completed the repair list, leaving a few items under watch for the time being. The travel bug is biting us again, and we’ll be hitting the road for a short jaunt soon!!

All our equipment may be falling apart, but we can still make music and have fun!

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Links to other RV tech and lifestyle articles:

• RV TECHNICAL Article Index – RV upgrades, modifcations, maintenance tips + what to look for when buying an RV
• RV LIFESTYLE Article Index – Lifestyle tips & costs, repairs we’ve faced on the road and living off the grid
• Product Review Article Index – Reviews of products we’ve used for RVing, cruising and photography

More articles and snapshots from the crazy lifestyles we’ve lived on the road and at sea:

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• 10 Years of Life on the Road by RV and Sailboat – The 2nd Half!
• 101 MORE Great RV Gift Ideas for RVers, Campers & Outdoor Lovers!
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• 2015 RV Travel Adventures – A Thrilling Journey East!
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• 2018 RV Travels – The Year of the Dog
• 50 RV Gift Ideas for Your Beloved RVer (or RV!)
• 5th Wheel Trailer Suspension Failure – Replaced with our RV Warranty!
• 9th Anniversary of Full-time Travel by RV and Sailboat – Reflections!
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• A Fleet of Leprechauns on the road!
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• Americas Mailbox – Mail Forwarding & So Much More in South Dakota!
• Around the World in an RV
• B&W Companion OEM Fifth Wheel Hitch Installation – Easy!
• Buddy – A Journey in Sprit
• Camping World Video Shoot — RVing is for Everyone!
• Canada RV Travel Tips – RVing Nova Scotia & the Canadian Rockies!
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• Choosing a Trailer for Full-time RVing: Cargo Carrying Capacity
• Choosing a Tripod – Sunwayfoto Tripod & Ball Head Review
• Circling the Wagons
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• Cold Weather RVing – Brrr… (or Ahhhh?!)
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• Finding a Fifth Wheel Trailer or Toy Hauler to be a Full-time Home!
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