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Old 05-27-2023, 08:50 PM   #1
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pohoda's Avatar
 
Brand: Thor Motor Coach
Model: Magnitude BH35
State: California
Posts: 61
THOR #23156
Upgrading to double steps from single - Thor Magniture/Omni

Upgraded to double steps like others have posted on here. Adding additional details for those looking to DIY and want to save a little $$ sourcing the step frame and correct gear motor and actuator arm at a fraction of the price of a full assembly. Having a helper is suggested to help hold the stairs in place or you can rig up some stands or use a jack to help.
Parts needed:
  • Kwikee 32 Series Step (Frame Only) - 3722618 -https://a.co/d/102avtK (can be sources used on like new on FB marketplace for as low as $100)
  • Kwikee 379160 Gear Box Linkage with A - https://a.co/d/5dah5jM(I suggest buying the original Kwikee and not one of the many knockoffs. The cheaper knockoffs have inferior parts and will leave you with inoperable stairs in short order)
  • Motor, amber light, and controller from original single step
  • Nylon zip ties
  • Spray on lithium grease
  • Rags and latex gloves
  • Alternately you can buy the entire Kwikee 32 Series Electric Step Assembly with Standard Drive Operation and No Switch Kit for RVs which is more of just a plug-and-play replacement for the Thor factory single step. If you go this route you don't need the above parts. - https://a.co/d/2wp2FNc
  • Tools needed
  • 3/8" ratchet with 4" extension and 9/16", 10mm, and 7/16" socket
  • Needle nose plyers
  • Hammer
  • flat head screw drivers
Instructions:
1) Remove single step from RV.
I recommend keeping the entry door open when doing this to prevent the step from activating when you are working on it. Make sure the step is extended before you start. Disconnect the power plug from the existing step underneath. Next remove any ground wires that are secured to the frame or other metal parts so the step can be removed without obstruction. Unplug the motor so you can remove it completely. Remove the (3) bolts holding the motor in place using a 3/8" socket. There will be grease on the gear so this would be a good time to have some rags handy. Remove the motor and set aside to be used later. Have a helper ready to hold up the stairs and place a board or similar items below the steps to lower down on. You can even use a bottle jack or similar approach, but plan this out before you fully removed the bolts. Remove the (4) 9/16" bolts that hold the step frame to the bottom of the RV and lower off the stair assembly. Bring the original step assembly and place it next to the new double step assembly.

2) Mount the new gear box you ordered with the curved arm to the new double steps.
You will need to removed the carriage bolts and nuts from the original gear box and reuse those to mount the new gear box. Install the gear box in the correct orientation so that the arm can attach to the stair actuator bracket. You will also need the actuator arm pin and cotter pin from the original stairs to reuse with the new steps. You may want to replace the cotter pin at this time if it is damaged too much from removal. Using white lithium grease spray apply to the pin and other pivot points while you have access to everything. This also helps with installing the pin and arm as it is a pretty tight fit.

3) Install the motor logic box and amber light to the bottom of the new double step. They will attach in about the same manor as they were removed and the spots on the new step are identical to the original step in terms of mounting. Do not install the motor at this time as that will get in the way of accessing one of the 9/16" bolts to reinstall the steps. While the steps are out this is a good to time lubricate all the pivot points on the steps with lithium spray grease. You can also choose to do this after you install. Be careful while moving the steps as they will accordion at this point and there are several pinch points that can get you. They are also quite heavy so having 2 people or some type of furniture dolly is helpful to move it into position. I also raised up my hydraulic jacks to provide more clearance.

4) Install the new double steps under the coach using the mounting holes that align with the bolts hanging from the coach. There are several mounting holes for different applications, but there are only 4 that will align so it should be self evident which one to use. This is the hardest part of the install and having a 2nd person or some type of jack will help to lift it into position. Install the (4) 9/16" lock washers and bolts and tighten. Once tightened take care not to get your fingers in the wrong place to avoid getting pinched or crushed. The steps will move on you during this time. Check the motion of the steps and assure they are working in full motion with no obstructions.

5) Prepare the motor to be reinstalled into the gear box. You will need to have the (3) 10mm bolts ready and check that there is sufficient grease on the gear on the motor and in the gear box. When ready have a helper hold the steps in the fully extended position and install the motor back. The helper should not let go until you have fully secured the motor as it is what bears the weight of the steps from closing. Reconnect the motor wire and secure using the included metal clips. Use zip ties to clean up any other wires and be sure to re-secure all ground to metal as they were before. Finally connect the step controller wire back to the coach connection taking caution not to have any fingers etc in pinch zones.

6) Test the stairs and make sure you have full motion outward and inward. The steps should hit the stops in both cases.
A few other observations I had were that this double steps take a little longer to open close as the motor has to travel further using the same gear ratio.

Disclaimer: I take no responsibility for any damage or injury caused by you attempting this yourself. This is just to share information and if you decide to do this yourself you do so at your own risk.
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__________________
2020 Thor Magnitude BH35
Mods: VROOM full slide upgrade, Banks derringer, iDash, pedal monster, and CAI. Bilstein 4600 shocks and steering stabilizer, Sumo springs, HornBlaster Conductor's Special 5485 Nightmare Edition Train Horn Kit with onboard compressed air, TPMS kit for 6 tires, upgraded TVs to smart TVs using Google TV.
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