Tuesday, 19 August 2025

The Truth About Hymer Habitation Door Hinges: Myths, Fixes, and Simple Solutions


The Truth About Hymer Habitation Door Hinges: Myths, Fixes, and Simple Solutions

NOTE - This article is AI generated, but based on real world info, and edited and checked by me.

For owners of classic Hymer motorhomes made up until the mid‑1990s, one of the most common headaches is the habitation door hinge. These aluminium hinges, after decades of use (and often years without proper lubrication), are prone to seizing up or snapping outright.

For years, motorhome owners have shared stories of broken doors, expensive replacements, and various "solutions" ranging from plastic 3D‑printed hinges to hand‑machined aluminium reproductions. But Ron Bentham – a former metalworking engineer and long‑time Hymer owner – argues that none of these options are really necessary.

In fact, he insists the fix is simple, affordable, and reliable.


Why the Original Hinges Fail

Hymer’s habitation door hinges were originally aluminium extrusions. Over time, exposure to the elements and lack of lubrication leads to the hinge pin seizing in its socket. Once this happens, the huge leverage of the habitation door works against the seized joint, and the brittle alloy hinge body cracks or snaps.

Ron warns that many owners don’t even notice their hinge has seized until it’s too late:

“If your door moves, but stops dead when you stop pushing – instead of swinging freely – then a hinge has seized. That needs emergency attention.”

When a hinge does crack, most people choose replacement — but it isn’t the only option. Being aluminium, hinges can sometimes be repaired by a skilled metalworker with aluminium welding facilities (often a case of who you know rather than an everyday retail solution). In less severe cases, owners have managed to extend a hinge’s life by drilling extra screw holes for fresh fixings, or fitting a large washer to spread the load.

Different owners have different levels of skill, tools, and facilities — so while repairs are certainly possible, replacement remains the easier route for most.


The “Special Hymer Hinge” Myth

Because the originals are no longer manufactured, some suppliers stepped in with alternatives:

  • 3D printed plastic versions: Lightweight, usually promoted with great enthusiasm online, but rarely proven in the long term. As Ron dryly points out: “The originals were metal. Why replace them with plastic? That’s just pointless.”
  • Hand‑machined aluminium replacements: Beautifully made, but prohibitively expensive. Owners frequently report quotes of £100 or more per hinge – and with four hinges required per door, the total is extraordinary.

This inflated market is driven by the perception that Hymer hinges are “special” and cannot easily be replaced. But according to Ron, that simply isn’t true.

“It’s just a hinge. There’s zero reason to pay a hundred quid for it.”


The Common-Sense Fix: Ellbee Caravan Hinges

The closest near‑match for the originals is the humble Ellbee caravan door hinge. These are still readily available online and in caravan parts shops, typically costing under £40 for a full set of four.

What makes them so good?

  • They are almost identical in profile and function.
  • At most, they require minor modification (a little drilling or adjustment of screw spacing).
  • They’re made from metal, just like the Hymer originals.

Some owners report that no modification at all is necessary for a direct swap. Ron himself advises simply buying a spare set at today’s low price, given how cheaply they can be sourced compared to custom-made options.

“At £7 each it’s a no‑brainer,” he says.


Beyond Ellbee – Other Practical Options

While Ellbee hinges are the closest direct replacement, it’s worth noting that many Hymer owners have solved the problem simply by browsing hardware shops and picking from the thousands of different hinges available. As long as the replacement is sturdy enough and allows proper door alignment, there is no magic “Hymer‑only” specification.

One owner even recounts replacing his broken hinge with a simple steel one found in a Moroccan hardware shop. It wasn’t elegant, but it worked.


Preventative Maintenance: Don’t Let It Happen Again

The cheapest solution of all is to avoid hinge failure in the first place. Regular lubrication prevents seizing, which in turn prevents the stress that causes alloy to crack.

Hymer specialist Chris Womble stresses the importance of checking and maintaining hinges before they fail. His top maintenance tips are:

  • Check movement: If the door doesn’t swing freely when pushed, at least one hinge is binding.
  • Lubricate annually: Remove the hinge pin if possible, clean thoroughly, and lubricate with appropriate grease or penetrating oil.
  • If seized: Unhang the door and free the hinge with penetrating fluid. In stubborn cases, use a vice and hammer to work it loose – or even gentle heat with a blowtorch if all else fails.

Conclusion

The Hymer habitation door hinge problem has been overcomplicated for too long. While 3D‑printing enthusiasts and specialist machinists have pushed expensive or experimental solutions, the reality is simple:

  • A set of Ellbee caravan door hinges is almost identical to the originals.
  • They cost a fraction of custom parts and only require minor tweaks (if any).
  • Repairs can be possible for those with access to welding or DIY ingenuity.
  • Preventative lubrication and care will ensure many more years of reliable service.

As Ron – who has hands‑on experience and an engineering background – says plainly:

“Don’t pay silly money. Buy Ellbee hinges, modify if necessary, and get on with enjoying your van.”

 


PHOTO GALLERY - COLLECTED FROM VARIOUS SOURCES 

An original hinge - how is it attached? It has claws on the back!



The following photos are of an Ellbee conversion.












end of Ellbee photos

A hinge is a hinge! This unknown owner went his own way .... but it works.







A selection of hardware store steel hinges 


3D printed hinge - not enough info to recommend or criticise ...






Sunday, 3 August 2025

The Classic Hymer Electric Step

 The Classic Hymer Electric Step

The classic Hymer electric step is a powered platform located under the habitation door of the motorhome. It extends and retracts at the push of a button, making entry and exit easier. This article mainly concerns pre-1995 vans but also applies to a few post-1995 models.

Core Components

  • Step Motor and Cog Assembly:
    A 12V electric motor drives a toothed cog engaging a matching toothed quadrant, which moves the step smoothly in and out.

  • 12V Power:
    The motor receives its 12V power directly from the motorhome’s battery to operate the step. The warning light and buzzer circuit are powered by the battery but only when the ignition key is turned on. This prevents unnecessary battery drain when the vehicle is off.

  • Step Operation Switch:
    A Double Pole, Double Throw (DPDT) momentary switch controls the motor. The switch reverses the polarity of the 12V supply, so the motor spins in either direction—press one way to extend the step, the other to retract it.

  • Limit Switch:
    Located at the top of the mechanism opposite the motor, this “open to make” limit switch operates a warning light on the dash. +12V (with ignition on) connects to one side, ground on the other. When the step is fully extended, closing the switch completes the circuit, lighting the warning light. When retracted, the switch opens and the light goes out. The switch is similar or identical to common motorcycle brake light switches; part numbers like Hella 937171 and Durite 05791 have been suggested by owners as suitable replacements.

  • Warning Buzzer and/or Light:
    Alerts the driver if the vehicle is moved with the step extended. This differs by base model:

    • In Fiat-based Classic Hymers, the existing Fiat brake warning light serves this purpose. Fiat owners often get confused by this because if they drive away with the step left down, the brake light remains on, making them think they have a brake problem. Fortunately, after a few instances, most get used to this.

    • In Mercedes-based Classic Hymers, Hymer installed a separate, dedicated red warning light mounted on the dashboard or in the driver’s view. Unlike other Mercedes indicator lights, this light is unmarked with no symbols or text, illuminating only when the ignition is on and the step is extended.

    • Buzzer: Some vans have a buzzer that operates alongside the warning light. These are usually dealer or owner modifications and are not part of the original factory setup.

Troubleshooting

  • Switch Wear
    Switch failure is common after 20 or 30 years. Problems can be due to wear inside the switch or corrosion on the spade connectors. The switch is a standard rectangular DPDT (On)-Off-(On) momentary rocker switch (about 30mm x 22mm). For authentic replacements matching the original style, Marquardt (German-made) switches are recommended. Often, moving the spade connectors a few millimeters can clear corrosion and restore function.

  • Motor Failure
    The 12V motor can fail mechanically or electrically. Hymer used a standard motor common in electric window systems. Compatible parts known to work include:

    • Land Rover RTC 6640

    • Land Rover RTC 3821

    • Mercedes 0130821219

    • Mercedes 0130821016

    • Brose 187933-000

    These motors have an 8-tooth cog; others with more teeth won’t fit correctly. A common failure cause is dirty water ingress. Many owners successfully strip, clean, and reassemble their motors to restore function. A helpful YouTube video titled "Hymer step motor" demonstrates this.

  • Blown Fuses
    A blown fuse can cut power to the motor or warning system. The step motor is usually powered from the nearest habitation circuit. On pre-1995 models, this is often one of the top three fuses in the Hymer fuse panel. Later models with an EBL mark the step fuse as "Trittstufe" (German for step).

  • Quadrant Wear
    Teeth on the quadrant can wear over time, causing jerky or irregular step movement. New quadrants are available but costly. Some owners repair this by welding and filing new teeth.

  • Exposure to Elements
    Dirt, moisture, and grime cause corrosion and mechanical issues. Cleaning the step and wiring often restores operation.

  • Accidental Damage
    Driving with the step extended can cause it to hit obstacles, pushing it out of alignment. Classic Hymer steps are solid steel and can often be repaired by hammering or bending back into shape.

  • Manual Retraction
    If the motor or wiring fails, the step cannot retract electrically. To retract manually:

    1. Remove the three bolts securing the motor.

    2. Remove or secure the motor out of the way.

    3. Push the step back up by hand.

    4. Secure it with ties or straps.

    Some owners find manual operation acceptable and convert the step by removing the motor entirely, allowing the step to drop by gravity and be pushed back up by hand. To hold it securely in the up position, a slide bolt or turnbuckle (available in hardware stores) can be fitted.

  • Red Warning Light Flickers or Stays On When Step Is Up
    Usually caused by slight misalignment between the step and limit switch. Adjusting alignment typically fixes the issue.

  • Idiosyncratic Design: Random Intermittent Failure
    The step sometimes refuses to operate despite everything appearing functional, causing frustration. The best remedy is to tap or vibrate the step near the motor while pressing the switch. Many owners carry a rubber mallet for this trick.

Summary

The classic Hymer electric step is a simple, if occasionally quirky, system: a battery-powered motor drives teeth to extend or retract the step, and a limit switch triggers a warning light if the step is out while driving. Mercedes models have a distinctive unmarked red warning light, Fiat models share the brake light, sometimes causing confusion. Common issues include worn switches, waterlogged motors, and intermittent electrical quirks. Many owners swear by a well-timed tap (rubber mallet optional) to keep it working. With some care and experience, this trusty step keeps you rolling… or at least trying to!

PHOTOS - in no particular order.









step quadrant repair



limit switch location



manual conversion

merc warning light

step mounting bolts

this is how bad it can get


limit switch location