Fuel Filter Location on the 1997 Rexhall Aerbus

The fuel filter on a 1997 Rexhall Aerbus is mounted underneath the coach, along the driver's side frame rail between the fuel tank and the engine. You'll find it bolted to the frame roughly midway between the rear axle and the engine compartment. The filter sits in a horizontal position and is roughly cylindrical, about 10 inches long and 3 inches in diameter, with inlet and outlet ports on each end.

Access is easiest from below the coach. You'll need to raise the Aerbus on jack stands or drive it over a pit to get underneath safely. The filter location means you won't need to remove any major components to reach it — just clear away any debris or protective shielding around the frame rail in that area.

Key Takeaways

  • The fuel filter sits on the driver's side frame rail, roughly midway between the fuel tank and engine, and is accessed from underneath the coach.
  • You will need jack stands or a pit to safely work underneath the Aerbus, as the filter cannot be reached from the engine compartment.
  • The filter is held in place with a single bolt or bracket clamp, and fuel lines connect to ports on both ends using standard hose clamps.
  • Fuel will drain from the filter when you disconnect it, so have a drain pan ready and dispose of the old fuel properly.
  • Replacement filters for the 1997 Aerbus are available through RV parts suppliers and some general automotive retailers that stock motorhome components.

What You'll Need to Remove and Replace the Filter

Gather these items before you start: a wrench or socket set to fit the mounting bolt (typically 9/16 inch or 5/8 inch), two hose clamps or a hose clamp tool, a drain pan to catch fuel, a new fuel filter rated for your engine type, and fresh hose clamps if the old ones are corroded or damaged. You may also want a flashlight or work light, since the underside of the coach is dark, and a pair of work gloves.

Check your owner's manual or the old filter itself for the correct replacement part number. Rexhall used different engines in the Aerbus depending on the model year and configuration — typically a Cummins or Ford diesel, or a gasoline engine — so the filter size and thread size vary. Using the wrong filter can cause fuel system problems or leaks.

Steps to Access the Fuel Filter

First, park the Aerbus on level ground and turn off the engine. Let it cool for at least 30 minutes so the fuel system depressurizes and cools. Raise the coach on jack stands placed under the frame rails, never under the slide-outs or body panels. Position the stands on both sides for stability.

Locate the fuel filter on the driver's side frame rail. You may need to remove a plastic or metal shield that protects the undercarriage. Once you have clear access, position your drain pan underneath the filter to catch any fuel that spills when you disconnect the lines. Fuel will drip even from a filter that appears empty.

Loosen the hose clamps on both the inlet and outlet fuel lines using a wrench or hose clamp tool. Twist the hoses gently to break them free from the filter ports, then slide them off. Some fuel will drain into the pan. If the hoses are cracked, split, or very stiff, replace them along with the filter.

Removing the Old Filter and Installing the New One

Unbolt the filter from its mounting bracket or frame clamp. Most 1997 Aerbus models use a single bolt through a bracket. Keep the bolt and bracket — you'll reuse them with the new filter. Set the old filter in the drain pan to finish draining, then dispose of it and the old fuel according to your local hazardous waste guidelines. Do not pour fuel down a drain or into the trash.

Position the new filter in the same orientation as the old one, with the inlet port facing the fuel tank and the outlet port facing the engine. Bolt it back into place and tighten the mounting bolt snugly — do not over-tighten, as the filter body can crack. Reconnect the inlet fuel line first, then the outlet line, and tighten both hose clamps firmly. The clamps should be snug enough that you cannot twist the hose by hand, but not so tight that you crush the hose or strip the clamp screw.

Testing for Leaks Before You Drive

Before you lower the Aerbus or start the engine, inspect both fuel line connections for drips. Turn the ignition key to the "on" position without starting the engine — this primes the fuel system and pressurizes the filter. Wait 10 seconds, then turn the key off. Check again for leaks around both hose clamps and the filter body itself.

If you see fuel dripping, tighten the hose clamp a quarter turn and recheck. If the leak is at the filter body or ports, stop and do not start the engine — you may have a cracked filter or a mismatched replacement. Start the engine only after you confirm no leaks. Let it idle for 2 to 3 minutes, then turn it off and inspect one final time underneath before you lower the coach and drive.

Common Issues and What to Watch For

Fuel filters on older motorhomes often stick in place because the fuel has gummed up the ports over time. If the hoses won't budge, explore penetrating oil around the connection and wait 15 minutes before trying again. Twisting gently while pulling usually works better than yanking straight out.

Hoses that are hard and brittle should be replaced even if they don't look cracked. Old fuel hose can fail suddenly once the system is pressurized, and a fuel leak under a motorhome is a serious fire hazard. Automotive fuel hose is inexpensive and takes only a few extra minutes to swap out while you're already underneath the coach.

If the new filter leaks at the ports even after you tighten the clamps, the filter threads may be damaged or the replacement may be the wrong size. Stop when ready and verify the part number against your manual or the old filter. Driving with a fuel leak is not safe.

Frequently Asked Questions

How often should I replace the fuel filter on a 1997 Aerbus?

Most motorhome manufacturers recommend replacing the fuel filter every 10,000 to 15,000 miles or once per year, whichever comes first. If you store the Aerbus for the winter or off-season, replace the filter before you put it back into service. Fuel degrades over time and clogs filters faster in stored vehicles.

Can I replace the fuel filter without raising the coach on jack stands?

No. The filter is mounted on the frame underneath the coach, and there is no safe way to access it from above or from the side without lifting. Always use proper jack stands rated for your motorhome's weight. Never work under a coach supported only by a hydraulic jack.

What if fuel sprays out when I disconnect the lines?

This means the fuel system is still pressurized. Turn off the engine, let it cool for 30 minutes, and try again. If pressure builds up again when ready after you turn the key off, the fuel pump may be faulty. Stop and have the fuel system checked before you continue. Do not ignore this — a pressurized fuel system can cause serious injury.

Are there different fuel filters for diesel and gasoline Aerbus models?

Yes. A 1997 Aerbus with a Cummins diesel engine uses a different filter than one with a gasoline engine. The threads, flow rating, and micron rating all differ. Check your owner's manual or the old filter to confirm which engine you have, then order the correct replacement. Installing the wrong filter can damage the fuel system.

Can I reuse the old hose clamps?

If the clamps are stainless steel and not corroded or damaged, you can reuse them. If they are rusty, cracked, or the screw is stripped, replace them. New hose clamps cost a few dollars and are worth the peace of mind. Fuel system leaks are not worth saving the cost of a clamp.