Every time we go out for an extended trip, it seems that something always goes wrong in our 2011 Interstate.
Fortunately, the issues are usually more annoying that serious. But this one took the cake.
We went out for a week getaway. This morning, we woke to a heavy rainstorm. Unfortunately, the storm made it's way inside the van, with a torrent of water dripping from the AC unit.
When I got home later, and in dry weather, I inspected the AC unit on the roof. I noticed that the unit could not be installed as designed on the flat roof because, well, the roof isn't flat, but has raised panels along the length of the vehicle. The AC unit is just a bit longer than the two raised panels, so it sits a bit higher off the roof in the front and rear than the weather seal is tall. I suspected the leak was around this not well sealed area and sprayed water around it and sure enough, water came dripping inside, just like the rain.
I removed the cover to the AC unit inside and discovered that the installer slopped some SIKA between the original OEM seal and the roof around the perimeter to try to make up the space. He was a bit stingy in a few areas. The unit is mounted by placing the top unit on the roof on the seal, and bolts from the bottom then pull it snug and compress the seal, and hold it on the roof to keep it from flying off. The installer didn't bother to snug down the three bolts that hold the AC to the roof, as they were only hand tight. That's right. The entire unit was held on the roof wit loosely held bolts. Simply tightening them may have resolved the leak, but I won't know until my next water hose test. I may add more SIKA as well around the inside perimeter.
So, if you have water dripping from the AC unit in a heavy rain, check out the bolts that hold the unit to the roof.
So, in a summary, here's what has gone wrong on trips with my Interstate:
1. On delivery, I found that the counter-top was mounted against the wardrobe which popped annoyingly on every little bump. I fixed it by removing the counter-top, and moving it over about 1/16 of an inch. I also smelled propane, and found that the gas lines on the stove was only hand tightened as well.
2. Backup monitor failed. Twice. Third time I found a wire that was not making good contact and probably was the cause of the failure of the first two backup monitors. After I fixed it myself, no more problems.
3. Door window incorrectly installed and leaked (the seal was not placed correctly). Fixed by dealer under warranty.
4. Crack developed in upper right corner front in shower. Tried to fix twice under warranty, but crack keeps coming back. Have to take it to a dealer for another attempt.
5. Insulation in bath vent broke, and was flapping in the wind. Replaced with weather stripping myself.
6. Toilet paper holder plastic cracked because of improper use of power drill. AS sent me another and I replaced it myself. Still leaks though.
7. Same problem with MaxxFan, but the fan itself later failed and MaxxFan was kind enough to send me a new unit, that I replaced myself.
8. Backup preventer valve on black water flush line broke, allowing water to spill into van. I removed it and fixed it myself.
9. Bath mirror rusted and was replaced under warranty.
10. Sewer hose has developed leaks and now needs to be replaced.
11. Awning warning buzzer keep buzzing for no reason. Disconnected it per AS's recommendation.
12. Numerous squeaks and rattles which I have fixed myself, mostly.
13. TV is mounted in the wardrobe door, but I had to make a modification to the mount to see the image without it being washed out. This is more of a poor design, than fit and finish, though. AS no longer mounts them in this way.
14. Vertical trim on wardrobe is coming off, and when I open the upper locker, it hits it. Needs another nail or two to keep it in place.
15. Smaller burner on stove does not auto-light. Can't figure out why or how to fix it.
16. Shower will never drain no matter how level. The floor has a hump in the middle. I have to squigee water into the drain.
17. No insulation behind bath wall, which turns into a microwave in the sun. I put as much insulation behind there as I could reach and some foil type insulation but it still heats up in a few spots.
I previously had a Roadtrek Adventurous. It had two issues in five years. A screw on the front bumper pierced a wire on the chassis which had to be repaired, and the sewer hose had to be replaced. That was it. I am a little over two years into my Airstream.
I wonder what will go wrong next time out. I'll let you know.