Fixing a seized Toyhauler Fuel Pump - Polaris RZR Forum - RZR Forums.net
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post #1 of 46 Old July 8th, 2014, 04:11 PM Thread Starter
 
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Fixing a seized Toyhauler Fuel Pump

This is a writeup of troubleshooting and fixing the fuel station pump on our toyhauler. If yours has inexplicably died recently, read on.



If it's gonna fail, here's the worst place



Our Toyhauler - a 24' Shockwave - recently refused to dispense fuel from the fuel station. This is after we'd seen our friends suffer the same failure. Of course, it happened in the worst of all places - the middle of the Black Rock desert on a long weekend

The pump just wouldn't run. The usual whirring of the electric motor was absent when we'd turn on the pump. Electrically, everything seemed fine, although the pump motor became frickin hot.

Dang.



The suspect fuel pump



When we got home, I started researching a replacement. These varied from $150 to $200, depending on which highway robbery RV place we chose. So, I started researching how to diagnose (and possibly fix) the issue.

Historically, these pumps have failed for the following reasons:
  • Debris from the fuel tank have jammed the pump gears
  • The pump gears have swollen, and jammed in the gear case
  • Motor failure (very rare) from broken magnets

The primary cause has been swollen gears, so that's what I started to chase down.
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post #2 of 46 Old July 8th, 2014, 04:13 PM Thread Starter
 
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Re: Fixing a seized Toyhauler Fuel Pump

Diagnosis

Before I began, I heeded the horror stories of fuel fires, and deployed a fire extinguisher.


Safety first!



Next, unbolt the pump.





This allows the pump to slide out. This is important for a variety of reasons.


The loosened pump assembly. The supply and dispensing hoses are still attached

The first thing you need to do is roll over the pump and note the serial number, model, date of manufacture, etc.



The pump's data plate



Next up is exposing the gears of the pump. There's 4 bolts that hold the cover plate in place.





The pump case contains about a cup of fuel, which will drain out as you loosen the cover.


Note to self: replace my head with a catch basin next time



Remove the gearcase cover.


Sliding off the cover. Take care not to lose the o-ring!



This exposes the pump gears. Carefully remove them, looking for debris - gravel, shavings from drilling holes in the tank during manufacture, etc. - as you slide them out.


Avoid the temptation to pry with a screwdriver, you'll regret it



So, here's the parts you should have by now.


Gear cover, o-ring, pump gears and (very important!) drive bar



The number one cause of pumps seizing has been swollen gears. The plastic material has been vulnerable to new fuel formulations, especially alcohol or MTBE. This causes the gears to jam against the gear cover. Hot (desert) climates makes the problem worse.

You can see this in the above picture - the gear cover has etched in marks from the oversize gears.

To confirm this, I measured the gears.


Oversize gear. Also, the white plastic is a giveaway.

The stock gears measure 0.752", so no wonder these swollen gears jammed!

At this point, I briefly ran the pump motor. It spun freely, so indeed the issue was with the gears (there have been a few that had cracked magnets which bound up the motor). Since the motor ran, and there was no debris in the gears or gearcase, the problem was the swollen gears.
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post #3 of 46 Old July 8th, 2014, 04:13 PM Thread Starter
 
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Re: Fixing a seized Toyhauler Fuel Pump

Repair


The first thing I did was call GPI, who manufactured my pump. To save you the time, here's the phone number:

Great Plains Customer Support: 800-835-0113 or 316-686-7361

They told me they did indeed have a problem with gears being the wrong plastic; the changing formulations in fuels caught them by surprise, and they had a rebuild kit they would send me for free, since our pump was still in warranty.





If yours is out of warranty, or, you'd like to really confirm that the gears are the problem, here's the procedure.

After measuring the gear thickness, get a new sheet of 220 grit sand paper. Place it on a flat surface.


"Grinding the gears", ha ha



Using a figure eight pattern, sand the gear down on both sides. Using any other pattern, such as side-to-side, or circular, will result in in a profile that is not flat.




At the time, I didn't have the new gears, so I went to 0.748". It worked fine



Re-assembly (see below) with these sanded gears will confirm that the problem was swollen plastic.

After three days, the new gears arrived from GPI.


The new gears - somewhat over-packed.




Old (L) and New (R). The kit comes with a new drive bar, don't lose it!



After cleaning out the gearcase, I found that replacing the driven pump gear first made it much easier.


The drive gear, with the drive bar slid in place



After placing the drive gear, it is easy to place the second gear.

Inspect the o-ring, and slide the gear cover into place. The manufacturer says to use 90 to 100 inches of torque.


The steel bolts are easy to strip the aluminum case, be careful...!



From here, I left the pump unsecured. Then, I turned on the battery to test the pump.





Made sure the pump switch was in the off position


To avoid damage, this switch should be OFF unless you're actually pumping fuel



And finally, turned on the timer.


LED is lit - ready to test the rebuilt pump



From here, I went back to the fuel station, and turned on the switch. Voila! The pump whirred reassuringly, and I was able to dispense several gallons to test the pump.





After dispensing several gallons, I let the pump rest for several minutes, then checked for leaks. There being none, I re-secured the pump assembly.

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post #4 of 46 Old July 8th, 2014, 04:15 PM Thread Starter
 
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First Name: James
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Re: Fixing a seized Toyhauler Fuel Pump

Summary

That was pretty easy. As a bonus, I went from $200 down to $0.

Stuff I learned:
  • Only run the pump when you're actually dispensing.
  • No more than 15 minutes of dispensing at a time. (after that, 30 minutes cool down)
  • Install a fuel filter upstream of the pump, next on my to-do list.

Thanks for reading through this! I hope it saves someone some grief.


All the best, James
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post #5 of 46 Old July 8th, 2014, 05:45 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Nice write up.




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post #6 of 46 Old July 8th, 2014, 05:53 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Nice write up. Pretty easy fix. An upstream fuel filter is on my list before next season.
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post #7 of 46 Old July 8th, 2014, 06:17 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Very nice write up! This is good info for all guys with TH and a fuel station.
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post #8 of 46 Old July 8th, 2014, 06:21 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Great info! Thanks for posting!
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post #9 of 46 Old July 8th, 2014, 06:50 PM
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Re: Fixing a seized Toyhauler Fuel Pump

I had this same problem a couple years ago. I did some research and found the same fix as you. I had shaved mine, called the manufacture to get some replacement gears. I told the guy that I had shave my gears in return he stated there was a bad batch of gears and they would swell up. Also they changed to a different material which will not swell up. He also said by shaving the gears I probably wouldn't have another problem. I am still using the same gears I shaved problem free.

Definitely a good right up.

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post #10 of 46 Old October 6th, 2014, 09:53 AM
 
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Re: Fixing a seized Toyhauler Fuel Pump

I bought a used toy hauler and the fuel station did not work. I did not troubleshoot too much but I read all the stories about the gears swelling so I ordered a new set. My local Tractor Supply actually carries them but I didn't know that until it was too late. After installing them, it still would not work. The motor actually wasn't even turning.

I took the whole pump apart this time and discovered that the plastic piece that holds the brushes had gotten hot and melted a little so one of the brushes was fused to it. I freed it up and sanded the plastic down and smoothed the brush until it moved freely in the slot. Then I reassembled it and it works the way it should. It was an easy fix that saved me a couple hundred bucks.

Desert noob
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post #11 of 46 Old June 28th, 2015, 11:49 AM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Thanks to the OP for the write up! After an hour my fuel pump is back in business. I have a 2013 Razorback TH and the pump is very similar to the one posted. For those that don't have a caliper for measurement, I sanded in a figure 8 pattern a dozen times on both sides of the gear. I got lucky with the trial and error method the first time.
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post #12 of 46 Old June 28th, 2015, 04:55 PM
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Re: Fixing a seized Toyhauler Fuel Pump

Just checked mine for the first time this year. Works still. Whew!
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post #13 of 46 Old June 28th, 2015, 05:19 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

Great write up thanks for the info.
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post #14 of 46 Old June 30th, 2015, 02:49 PM
 
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Re: Fixing a seized Toyhauler Fuel Pump

I bet that I have this issue but I can't seem to find the inline fuse on my fuel pump to check it. I have power at the timer but nothing at the pump. I pulled the wires and verified at the pump after finding no bad fuses in the panel. Anyone have an idea about how far from the pump the inline fuse is usually located? The wire routing is miserable to trace under my Thor Tahoe Fury 24tb.
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post #15 of 46 Old August 16th, 2015, 12:14 PM
 
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Talking Re: Fixing a seized Toyhauler Fuel Pump

Thank you for your post! You saved us a bunch (of money, heartache, aggravation, etc). Our fuel pump has been giving us grief for about a year. It would work when the weather was cool but would stop working when it would get hot. It eventually stopped pumping. Swollen gears makes perfect sense. We do not have the caliper tool (the pump is long past being covered by warranty) and don't want to take the chance on sanding the gears so we ordered a new set of gears (comes with a set of gaskets) from BuyAutoTruckAccessories.com for 21.95 plus shipping which is a steal when compared to replacing the pump.

Gotta love the internet and people like you that post helpful solutions to problems! Thanks again!
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