Posted by Liana Harrow
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Living full-time in a van sounds free and adventurous-until your water pump dies in the middle of nowhere, your fridge stops cooling on a 90-degree day, or your battery bank drains before sunrise. Van life isn’t just about scenic views and coffee in the mountains. It’s about knowing how to fix things when you’re 200 miles from the nearest town. The difference between a smooth trip and a stranded nightmare? Regular maintenance and knowing what to do when things break.
Not every van is the same, but certain systems fail more often than others. Based on real-world reports from over 300 van lifers surveyed in 2024, here’s what breaks the most:
These aren’t rare glitches. They’re predictable. The key isn’t avoiding them-it’s preparing for them.
You don’t need a full workshop. But you do need the right tools to handle the top 5 failures. Here’s what fits in a 12x12x6 inch toolbox:
Keep this kit in an easily accessible spot-not tucked under the bed. You’ll need it at 2 a.m. when your fridge stops working.
Your sink drips. Your shower won’t turn on. The pump hums but doesn’t push water. That’s usually a failed diaphragm.
Most people buy a new pump for $150. Replacing the diaphragm costs $12 and saves you hours of waiting for parts. Keep two spares in your kit.
A dead battery is the #1 reason vans get stuck. But it’s rarely the battery’s fault-it’s the system around it.
Use your multimeter:
Here’s what the reading means:
If your battery reads below 12.0V after sitting for 12 hours, something is draining it. Common culprits:
Install a battery monitor (like Victron BMV-712) to track usage. It shows you exactly how much power you’re using-and if you’re overdrawn.
If your fridge runs but doesn’t get cold, it’s not broken. It’s misused.
Most van fridges are absorption models. They need:
Check the flame at night with a flashlight. It should be steady and blue. If it’s orange or weak, clean the burner tube with a pipe cleaner. Don’t use water-it leaves residue.
Van tires carry 30-40% more weight than car tires. They also sit longer without movement. That’s a recipe for sidewall cracks and blowouts.
Do this every 500 miles:
Replace tires every 4 years, even if they look fine. Rubber degrades from UV exposure and heat, not just tread wear.
Some fixes are DIY. Others aren’t worth the risk.
Call a mechanic if:
You can handle:
Don’t guess with brakes or steering. A $200 repair on the side of the road is better than a $20,000 hospital bill.
Keep a simple log. Write it in a notebook or use a free app like VanLife Tracker.
Every 1,000 miles:
Every 5,000 miles:
Every 12 months:
Stick to the schedule. Van life doesn’t reward spontaneity-it rewards consistency.
Even the best-maintained van can fail. Always carry:
Van life isn’t about avoiding breakdowns. It’s about knowing you can handle them. The more you prep, the more freedom you actually have.
You don’t need to replace the whole pump unless it’s cracked or the motor burns out. Most 12V pumps last 3-5 years, but the diaphragm inside fails every 12-18 months. Replace just the diaphragm kit every year or after 10,000 miles of use. It’s a $12 fix that takes 15 minutes.
No. Car batteries are designed for short bursts of power to start an engine. Van systems need deep-cycle batteries that can be drained 50-80% daily without damage. Use AGM or lithium iron phosphate (LiFePO4) batteries rated for deep discharge. A car battery will die in 3-6 months under van use.
Most van fridges switch to propane when battery voltage drops below 11.5V. If it’s not cooling on battery, your voltage is too low. Check your battery charge level, wiring connections, and inverter efficiency. A bad inverter can drop voltage even if the battery is fine. Use a multimeter to measure voltage at the fridge’s power input-not just at the battery.
Turn off the propane tank first. Disconnect the line and blow it out with compressed air. If you don’t have air, use a pipe cleaner to gently scrub the inside. Never use water or soap-it leaves moisture that causes corrosion. Reassemble and test with soapy water to check for leaks before using.
No. A cracked sidewall means the internal structure is compromised. It can fail without warning, especially at highway speeds or under heavy load. Replace the tire immediately. Even small cracks that look cosmetic can lead to blowouts. Van tires carry more weight than car tires-there’s no room for risk.