Balmar alternator or regulator fails to work as designed. No charging of batteries when idling or driving. This is a Safety Issue because fires have been reported as a result of these electrical system failures. Lithionics (battery) app confirms no charge reaching the batteries, see attached screenshots. Potential Risk of Fire when not working properly as evidenced by others with Balmar failures as reported to the federal safety agency. This is the 3rd failure we have encountered: 1st failure confirmed by Winnebago, and was replaced with like parts. 2nd failure occurred just prior to the 2023 recall, and was addressed by Winnebago Factory Service during recall by replacing parts again. 3rd failure occurred today. The current failure happened when the unit (2022 Winnebago EKKO) was parked in our driveway, not while travelling. Upon starting the vehicle, the alternator emitted a loud whining sound and subsequently provided no charging to the batteries. We are aware of the symptoms based upon our previous failures, and know of others who also had a Balmar failure after having the prior recall completed. We desire a lasting permanent solution for this problem as it has not been adequately addressed by the previous Winnebago recall.
2022 Winnebago Ekko electrical complaints
Page 2 of 2: complaints 11 to 28 of 28, newest first, as owners wrote them.
The prior recall #174 was completed at the Winnebago Factory Service Center in September of 2023. The replacement alternator failed and has now been replaced as a warranty item but the Factory Service Center. This is the 3rd Balmar alternator for this unit. The first replacement was approximately in October of 2022, then the recall was performed in September of 2023 which included replacement of the Balmar alternator, now that has malfunctioned once again necessitating replacement. All seem fail in one year increments.
40 amp fuse for Solar charger burned. Replaced fuse and fuse holder became too hot to hold with bare hand but didn't blow the fuse. This type of heat causes a risk of fire inside the motorhome. Currently unable to use solar, a significant element of our ability to enjoy the rig.
Winnebago serial number: [XXX] This vehicle has already had the recall work done as described in the federal safety agency Campaign Number 23V‑234. This work was performed at NIRVC in Las Vegas on or around February 7, 2024. Their work was excellent, however the Balmar alternator has once again failed. The prior electrical system recall was completed at the factory service center in Forest City Iowa. Additional service was performed before the recalls were issued at Colonial Airstream (selling dealer) in New Jersey and at Roam Rig in Connecticut. Please pressure the manufacturer to revise the recall and fix what has been a never-ending headache for almost all owners, since purchase. Thank you. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
After numerous prior repairs & recalls related to the Balmar Aux. charging system installed in our Ekko model RV by Winnebago, we again returned to the factory service center for the second time this year to have the latest recall, the federal safety agency 23V‑234 WGO Recall 174 completed. After the third day in the shop for the Balmar recall & other repairs the vehicle was returned to me. The tech advised me that 1 lithium battery from the dual set had to be replaced. After a quick visual inspection in the tech’s presence I pointed out several workmanship issues that required the coach to go back into the shop to correct before shop closing. That evening I drove the coach onto blocking to visually inspect their unseen work. I found several issues including a loose terminal connection of a high current 3/0 B+ battery cable at the newly installed alternator and an unsecured cable bundle dangling under the engine. I informed the service supervisor of my findings via email that evening & the next morning our coach was again taken into the shop for further recall corrections. That afternoon WGO insisted that I inspect the coach before they released it back to me for the third time. The coach was on the ground limiting my abilities so I accepted the vehicle with their assurance of a job done right. I next discover since the recall & one battery replacement, the batteries discharge at an uneven rate. After my emailing Lithionics it was decided to have WGO recharge each battery individually to try to balance the chemistry. That required a weekend stay & on Monday the tech completed the request. After returning the coach to me for the fourth time, I asked if he verified the batteries operation, he said he had not & we left in disbelief. Now, while discharge testing at about 1.9kw on our 2kw inverter the old batt discharge is 101A, the new is 50A, which is a serious problem. WGO tells me to go the local dealer which is no option. Looked like a good upgrade just very poor execution
Selling dealer preformed the federal safety agency #24V942000 Winnebago Ekko Recall # 165 in January 2022. The repair procedure held up delivery of the vehicle for months. A serious defect in their workmanship that could compromise the intended goal of correcting a potential hazard to nearby electrical components was later identified by me & reported to the dealer, and manufacturer. The dealers response was to deny that they performed the recall and reject that the area of concern, a sink drain line connection was part of the recall. I made it glaringly apparent that they were wrong in both regards & the dealer stopped responding to my request to correct. Reference WGO- Instructions To Perform Recall Campaign 165, pg 18 steps 74-77. I reported it to the manufacturer & in October 2023, after traveling 3400 miles round trip to the Winnebago factory service center, the defect was corrected. The dealer also failed to properly inspect or implement Winnebago Recall 7301, a correction of undersized battery cabling posing a serious electrical hazard. That also had to be reinspected and corrected on another visit to the manufacturer in March 2023. In reporting each of these instances to the manufacturer, the ultimate responsible party, I sensed a lack of interest from their representatives for their contracted agent's safe implementation of the necessary safety related repairs. These repair failures resulted in unnecessary inconvenience, potential safety risk to life and/or property and required us to take extraordinary measures to deliver the vehicle to the manufacturer twice within approximately 6 months for corrections. The dealer has failed to follow the manufacturer's clear & precise recall procedural protocols, approved by the federal safety agency and has shown a pattern of disregard for our safety. In the interest of public safety, I would hope that the federal safety agency would audit the offending dealer's service repair record related to Campaign #21V942000 and require an independent review for similar defects.
Balmar Regulator creating sparks under hood eventually blowing a fuse. Shows signs of a shorted wire somewhere in the vehicle.
The solar panels ceased to charge the batteries. I found a 40A Fuse holder behind the solar controller in the coach, that had melted and looked like it could have caught on fire.
The contact owns a 2022 Winnebago Ekko RV built on a 2021 Ford Transit Chassis. The contact stated that the Blind Spot Monitoring (BSM) system had stopped functioning. Additionally, the contact stated that upon starting the RV, the RV made abnormal whining sounds and there was a strong burning odor inside the cabin of the RV. The contact stated that she determined that the secondary alternator had failed after investigating the issue online. The contact stated that she opened the hood and disconnected the secondary alternator by disconnecting all the alternator pins from the regulator. The contact stated that the A/C foam insulation close to the alternator had melted and was burned. There was no warning light illuminated. The contact stated that she had received notification of the federal safety agency Campaign Number: 23V234000 (Electrical System), that the contact related to the failure; however, the part to do the recall repair was not yet available. The manufacturer was notified of the failure and scheduled an appointment with the dealer for November. The dealer was notified of the failure. The RV was not diagnosed nor repaired. The failure mileage was approximately 23,000.
The contact owns a 2022 Ekko Winnebago RV built on a 2021 Ford Transit Chassis. The contact received notification of the federal safety agency Campaign Number: 23V234000 (Electrical System) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.
Winnebago factory installed Blind Spot Monitor System did not work since purchase, after local dealers failure to repair this and other defects, out of frustration we drove it 3000+ miles to the WGO factory repair center located in Forest City, IA. BSM was repair by WGO on invoice #02942R dated 3-13-23 under warranty. BSM module was replaced, 2A protective fuse installed and wiring connections corrected. 10 days later during return trip home BSM failed while driving in heavy snow. Contacted WGO factory service supervisor with failure details and was told we could either bring it back or take it to the local dealer again. Local dealer repaired per their repair order Doc #190571 dated 6-23-23. After being advised it was repaired we picked it up and it did not work from dealers lot. Emailed WGO supervisor, dealer service manager & service advisor. Local dealer has not responded as of 7-5-23, 10 days later. WGO supervisor responded to take it back and have the dealer work with our tech department. I had previously given the dealer all of the factory contact info I have and they are in-fact a WGO Flying W certified repair facility. This is a safety issue and a defective factory installed accessory that continues to be an unresolved issue. In researching I found on Facebook under the group- Winnebago Owners & Wannabes a 5-19-2022 BSM failure survey in which 105 owners responded the following- 30% No Problems, 29% Stopped working after driving on wet roads, 7% Stopped working after driving in snow/salt, 24% Never worked, 1% disconnected because of annoyance, 9% Combined, stopped working after other or works intermittently. I did not respond but would have been in the Never has worked section. This and all the online chatter would seem to indicate a high rate of units either not working at delivery or failing sometime after deliver. This is a Voyager System integrated into a Ford Transit chassis by Winnebago. I would like to see these systems correctly repaired
Blind Spot Monitor is unreliable and unsafe. Causes false sense of positional awareness when changing lanes. Hundreds of other owners have reported similar complaints on social media. Winnebago has fixed the problem by using a Ford-based system on 2023 models but has mostly ignored previously manufactured EKKOs other than to attempt repairs that fail over and over again.
This is allegedly related to the Balmar relay system installed by Winnebago in the Ford Transit van.It is currently at the dealer, Colonial Winnebago, in Millstone Twp., NJ. Dealer can be contacted for inspection. We began traveling at a 25 mph speed for about 2 miles when smoke began to flow from under the hood. We pulled over to inspect; 911 was called. Smoke and flames under the hood were visible and continued until the fire truck came and extinguished the fire. Our safety and the safety of others was put at risk as the unit did not display any warning signs on the dashboard, there was a fire and smoke under the hood, we were in a public parking lot, and the unit carries 2 20 lb. propane tanks. Problem was diagnosed by our local Ford dealer, who stated that this is a Winnebago issue, as this was a Winnebago specific modification to the Ford. Unit was not drivable and needed to be towed to Winnebago dealer for service. They know about this issue - and have known for some time - but have not yet released the recall. We do not know at this time when the unit can be repaired. I do not know who has inspected the vehicle other than the Ford dealer and Winnebago dealer. No other warning signs or symptoms before the incident occurred.
The Balmar charge controller for the coach lithium batteries failed. The controller is rated for temperatures up to 90 C (194 F). Based on Ekko forum discussions I suspected the controller, which is located in close proximity to the passenger side turbocharger was overheating. I fashioned an improvised heat shield between the turbocharger and controller and after driving in 74 F ambient conditions measured temperatures of 285 F on the heat shield and 185 F at the controller surface. I also added heat shielding to the controller wiring, which is also very close to the turbocharger. Clearly without owner-added heat shielding, (and even with during higher than 74 F ambient temperatures) the controller is far exceeding it's allowable temperature maximum.
The auxillary alternator caught on fire. The dealer retained the part when replaced. Fire risk to ourselves and entire rig. Yes, the problem was confirmed by a dealer. The Yuma, Az fire department responded and wrote a report. There were no warning lamps, messages or other symptoms,
The secondary alternator caught on fire while traveling and damaged the Ford tensioner that supplies AC compressor power
Wiring harness and a fuse on the harness for the auxiliary Balmar alternator installed by Winnebago partially melted due to proximity to turbocharger. Very concerning due to other owners reporting Balmar alternator fires and alternator regulator failures.
The entire shower water after use was draining directly onto the inverter creating a fire hazard.
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