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Old 05-25-2017, 02:17 PM   #1
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Default 02 Roadtrek 200 popular AC rattles & squeaks (Physically, not electro-mechanically)

I posted this before under a different title and didn't get any replies. Thought I'd try with a more descriptive title. My apologies for the double post, but I couldn't figure out how to edit the title on the original post.

I've got a horrendous rattle and most annoying squeak coming from my Danby AC unit. It is physical, and not mechanical. Meaning, it is just with the unit powered off, driving down the road.

I have isolated it to the left side where it meets the wood of the left (passenger side) storage compartment. If I drive a couple of PVC or wooden "door and window" shims in between the AC unit and the wood, it cures 85% of the rattle & squeak.

This solution has a few issues. 1. Looks horrible. 2. After 3 miles on a poorly maintained roadway, the shims fall out. 3. Not very "elegant".

Further, there is a "tray" of some sort underneath it. I suspect a condensation/drip tray with an outlet somewhere. This "tray" has a lot of what looks like disintegrated "rock wool" insulation in it. I can get a few pieces out by hand, by the front of the tray. How much more is in there? Where did it come from? How do I replace it?

In addition to the questions above I ask:

1. Anyone else have this issue (squeak/rattle) and what did they do about it.

2. Any suggestions as to what to try?

3. How do I access/remove the AC unit to attempt my OWN modifications/repairs?.

Thanks.
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Old 05-25-2017, 05:02 PM   #2
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.

RVs rattle. That's just the nature of the beast.

RVs are not designed to go offroad or on badly maintained roads.
The potholes and ruts will tear the interior apart.

Having said the above...

if the fridge [edit] I meant AC, is falling apart,
maybe you should take it out and re-seat it.


.
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Old 05-25-2017, 05:46 PM   #3
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Not talking about potholes or ruts. Nor off-road. Just secondary roads that might be crowned, cracked the usual pavement defects etc. Nothing major. We travel on secondary roads a lot.

It's the AC not fridge. The fridge would be a breeze to remove compared to the AC.
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Old 05-26-2017, 05:26 PM   #4
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Default ac remove

On my 2002 popular 200 the ac is accessed from the outside on the roof there are several screws that seal a access cover to reach the ac unit. I would look at that cover to see if yours comes out the same way
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Old 05-26-2017, 10:21 PM   #5
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Also, if there is a cover that comes off, and you remove it, you cannot re-use the screws that come out. They are not screws but I believe they are called Well Nuts. If you should remove, take one to a Fastnel Store for exact match-up; sometimes you will find them at Ace or Home Depot. Ron
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Old 05-27-2017, 07:32 PM   #6
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Thanks for the tip Ron. I never even hear of a "well nut" until you mentioned them. Interesting.

https://en.wikipedia.org/wiki/Well_nut
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Old 05-29-2017, 03:39 PM   #7
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I would suggest avoiding to remove the AC. It's a tough job with lots of Silicone!

I can't really tell you how to fix it but I can certainly share pictures to give you an idea of the work involved. I replaced my AC did this weekend on my 1998 Versatile 200:

After the old AC was removed:


The new AC in place:

We added 1" and 3/4" aluminum angle iron to hold it in place. Before, there was just two screws on the side that go through the cabinet at an angle into the corners of the old AC. I think we did a better job!

From the inside:


(Limit of 4 pictures. Standby for the rest.)
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Old 05-29-2017, 03:42 PM   #8
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Where the drip tray is supposed to be:


What my drip tray looks like:

You can see that it's broken and patched up with weird material. You can also see that there's a tube that empties it out to the back.

I also found some foam inside the drip tray and my hypothesis is that it's there to prevent water from splashing around when you're driving. I suggest to replace it with any kind of foam made for a humidified that won't develop mold.
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