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Weather Pro Awning not moving

Posted 07-28-2021 at 02:16 PM by HiBanky
Updated 08-12-2023 at 12:38 PM by HiBanky (Add Photos)

I have a 2005 Journey with a Weather Pro electric awning that stop rolling the canvas in or out. The motor can be heard turning when either switch is pushed but no movement what so ever. Moreover the canvas can be rolled in or out by hand without removing the motor lock screw.

I concluded that the so called “stabilizer”, which is the cam like driver that fits the grooves in the roller tube and is attached to the end of the motor, has disconnected itself from the drive motor.

I removed the motor from the end of the tube following the direction from some good You Tube videos. (CAUTION) Be sure to follow the safety instruction as they apply to restraining the arm and supporting the roll.
After pulling the motor from the tube, I discover the stabilizer was not on the end of the motor. If you have a small hand, you can reach in and pull it out. If not, make a wire hook and fish it out. It may come out with the motor but it may still have the same problem in that it is not fully attached internally. To check this, give the stabilizer a good tug. If it comes apart, it is the same problem.

To fix this, line up the internal washer in the motor end and insert the stabilizer shaft back into the motor. With a small hammer, preferably brass, tap the end of the stabilizer to seat the shaft. Be gentle. If the shaft is properly seated it can not be separated by pulling with your hands. Reassemble and your done. Three new pop rivets is the only cost not a $400 motor.

This turned out to be only a temporary fix. It failed after 10 or 12 cycles in and out. So I removed the motor again and disassembled it as much as I could. In the process I discovered loose screws on the end under the stabilizer. This may or may not have contributed to it coming apart. What I discovered next was that the shaft is a press fit into the motor. I could also see that couple of light taps on the end of the shaft did not drive it fully in. So this time I tapped on the end more aggressively until I could see it was completely in as far as it could go. So far its working fine but time will tell.

update 8/18/2021
30+ cycles in and out and it is still working fine.

Now that the original problem has been solved, we have a new one. The awning stops and starts intermittently while operating it from the inside remote rocker switch but works fine from the switch on the control box. After disassembling the switch and checking all the wires, to no avail, I fined that one of the spade connectors inside the gang connector on the back of the switch was bent back and not making complete contact. Using a tiny jeweler's screwdriver to carefully bend it back solved the issue and all is working again.

Update 3/12/2023

After dozens of cycles in and out the motor connection remained intact and it appeared that it would continue to work indefinity. That is until I made the mistake of starting the engine while the awning was tied down with straps and earth anchors. As the air bag suspension filled and the coach raised up a good eight inches. Not only did this pull the anchors out of the ground but it separated the stabilizer from the motor again. I’m now convinced this is a built-in failsafe. Using the same method I use the first time, the awning is back together and working fine. Time will tell how long it lasts this time.

Update 8/10/23

It’s been a couple of years since the first time I repaired this drive motor. Since then the stabilizer separated itself from the motor several times. It seems that each time I fix it fails sooner than the last.

I use the same process to repair it each time. I’ve gotten good at it and now it takes only about fifteen minutes to complete the task. I also found that removing the motor with the awning fully extended is easier than with it up. The trick to this method is to strap a 6’ stepladder to the ground or heavy object and stick a large screwdriver in a hole in the top of the ladder. Remove the tube and motor from the extension arm and pull the motor out of the tube while supporting the tube with the other hand. Place the motor on the ladder. Then with the tube in one hand clamp or strap it to the top of the ladder resting it against the screwdriver handle. The extension arm can just hang there without support. It takes some talent so you may want to do a dry run first. If the ladder and tube are not secure it will all come crashing down causing damage, injury, or death. No Joke!

As mentioned, this has failed several times but this last one has caused me to rethink this continuing cycle of fail and repair. What drove me to this decision was an event I won’t soon forget. This time it failed just as a severe storm hit. In the night with high winds and drowning rain my wife and I are out holding on to the awning keeping it from flying away just as lightning strikes not 50 yards away.

I have purchased a new motor assemble and it goes in today. The new one is held together with a locking nut. Much better design.

See my new blog (Upgrade Weather Pro drive motor) for details on swapping out the arm attachment parts.
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