NHTSA ID Number: 10164608
Manufacturer Communication Number: P03-264
TSB/Document Date: 2019-09-09
Summary
This Procedure outlines the steps to check the engagement of the windshield and rework the front cap opening to prevent water intrusion on model year 2018-2019 J4500 model coaches.
Procedure 03-264
J Coach Windshield Water Leak
Description:
This procedure outlines the steps to check the engagement of the windshield and rework the front cap
opening to prevent water intrusion.
Replace non-MCI
supplied windshield, if present, with MCI windshield before starting this
procedure.
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and protective
gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Positioning the ENGINE RUN and ENGINE START switches on the engine compartment
remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the engine
compartment.
Page 1 of 16
Procedure 03-264
1.0
Special Tools:
•
•
Fencing tool
6-inch steel ruler
Fencing Tool P-101
2.0
Fence Engagement Inspection:
Place tape along the edge of the windshield fencing on the front cap.
Tape placed at the
edge of the fencing
Page 2 of 16
Procedure 03-264
Remove the lacing from the top of the windshield fencing.
The lacing removed from the top
section of windshield
.
Insert the fencing tool between the fencing and front cap to release the fencing from the cap.
Fencing tool
Use ruler to measure the engagement of the fencing to the front cap. Measure from the bottom of
the tape to the edge of the front cap. Measure the engagement at the corners and for every 6
inches in between along the top section of the fence.
The engagement measurement area
Page 3 of 16
Procedure 03-264
The fencing engagement should be greater than 0.25 inches on the ruler.
•
If the engagement is greater than 0.25 inches proceed to Section 3.0
•
If the engagement is less than 0.25 inches proceed to Section 4.0
Page 4 of 16
Procedure 03-264
3.0
Sealing Windshield Fencing
3.1
Material Requirement:
Service Kit T03-3012 contains the following parts:
ITEM
PART NO.
QTY
U/M
DESCRIPTION
1
T03-3011
1
EA
Adhesive-Urethane, 3M 08609
2
23-02-0122
1
EA
Primer-activator Teroson PU 8519p
3.2
Applying sealant to the windshield:
Use fencing tool to remove old sealant between the front cap and the windshield fencing. Clean
area with isopropyl alcohol to remove all debris and sealant.
Removing sealant and dirt from
area between fencing and front cap
across front windshield.
Apply primer 23-02-0122 between the fencing and the front cap and allow 5 minutes flash off
time.
Apply primer between fencing and
front cap.
Page 5 of 16
Procedure 03-264
Apply adhesive T03-3011 between the fencing and the front cap. Apply enough to fill the gap and
allow the excess adhesive to run out on the tape.
Apply adhesive between fencing and
front cap.
Reinstall the lacing.
Lacing installed in fencing
Let the adhesive dry for 20 minutes and clean up the excess that was left over. Remove the tape.
This procedure is complete
Procedure complete
Page 6 of 16
Procedure 03-264
4.0
Mocking Up Windshields
4.1
Material requirements:
Service Kit T03-3008 contains the following parts:
ITEM
PART NO.
QTY
U/M
DESCRIPTION
1
T03-3002
3
EA
Fiberglass Strip
2
T03-3003
3
EA
Stainless Steel Strip
3
T03-3004
2
EA
Gasket- Driverside 12-inch piece
4
T03-3005
2
EA
Gasket- Curbside 8-inch piece
5
T03-3006
4
EA
Gasket- Bottom 10-inch piece
6
T03-3007
2
EA
Gasket- Middle 10-inch piece
7
23-02-0127
1
EA
Epoxy-Pliogrip Plastic Repair-3
8
T03-3011
1
EA
Adhesive-Urethane, 3M 08609
9
23-02-0122
1
EA
Primer-activator Teroson PU 8519p
with tips
Additionally, use front windshield gasket 03-27-2045 as required.
4.2
Removing the fence:
Remove windshield wipers and lacing from the fence.
Remove trim pieces on the inside of the coach above driver seat and stairwell set aside and save
for later
Remove both pieces
inside coach
Remove windshield water hose.
Page 7 of 16
Procedure 03-264
Spray lubrication between fencing and glass and from inside of the coach start pushing out the
roadside windshield glass. Start at the top right side and go down. After that, push the top portion
of the window out and then left side of the window. Once half the glass is out slide window out of
the bottom groove of the fence and set aside for later use. This step requires another person on
the outside of the coach to hold the windshield.
Repeat the process for the curbside windshield.
Remove fencing from the front cap and set aside for later use.
Cover the dash from inside of the coach with a cloth to avoid dust from entering the coach.
Page 8 of 16
Procedure 03-264
Place two roadside gaskets, T03-3004, on the roadside post and two curbside gaskets, T033005, on the curbside post evenly spaced from top to bottom on outside posts. Place the two
middle gaskets, T03-3007, at the top and center of the middle post. Place two bottom gaskets,
T03-3006, on the roadside bottom track of the windshield and two bottom gaskets, T03-3006, on
the curbside bottom track of the windshield in an evenly spaced manner.
T03-3005 to be placed on
the curbside
T03-3007 placed on the
middle post
T03-3004 placed on the
driver’s side post
Place the roadside windshield in the T03-3006 sections on bottom track and install the windshield
into T03-3004 sections on the outside post and then into T03-3007 sections on the middle post.
Repeat the process for the curbside windshield
Install
windshield
4.3
Scribing Line:
With the calipers locked at 0.9” rest one pointer of the caliper on top of the windshield and scribe
a line on the front cap using the other pointer by running the calipers along the top of the
windshield
Scribe a line across
the front cap with
calipers
Page 9 of 16
Procedure 03-264
Adjust the bottom edge of the tape to line up with the scribed line
Tape lined up with scribed line to
mark how much material will be
removed
Remove both windshields in preparation to trim front cap.
Line scribed with calipers across
front cap
4.4
Trimming Front Cap:
Place an 80 grit D/A sanding pad on the sander and trim the front cap at the bottom of the tape.
Care should be taken not to trim at the corners
Remove material to the bottom of the tape
marking the scribed line
Leave this material on the cap. Do not
remove material from the either corner
Page 10 of 16
Procedure 03-264
4.5
Installing the Cap Extension:
Scuff both sides of T03-3003 Stainless steel Strip using 80 grit sandpaper and then clean with
isopropyl alcohol. Clean the fiberglass strip and front cap from inside of the coach with isopropyl
alcohol.
Scuff both sides of the stainless strip
Apply adhesive 23-02-0127 to the stainless-steel strip, T03-3003, and attach it to the fiberglass
strip, T03-3002. Use clamps to hold it in place. Allow 20 minutes flash off time
Attach the fiberglass and stainlesssteel strips
Clamp after bonding T03-3002, T033003 together
Page 11 of 16
Procedure 03-264
Apply adhesive 23-02-0127 to the stainless-steel strip, T03-3003, and attach it to the front cap
from inside the coach at center in such a way that the stainless-steel strip surface with holes is in
contact with the front cap and the fiberglass side of the strip is pointed outwards. Use the clamps
to hold it in place.
Extension is centered in middle of cap
On the curbside, measure the length of the front cap between the edge of curbside windshield
opening and left edge of the installed stainless-steel strip. Cut a piece of stainless-steel strip,
T03-3003, to the measured length and shape it to fit the contour of the front cap. Cut a piece of
fiberglass strip, T03-3002, to the just cut stainless steel strip length and shape it to match the
contour of the stainless-steel strip. Score slots on the back side of fiberglass strip, T03-3002, to
match the shape of stainless steel strip.
Shaping Stainless Strip to fit contour
to windshield opening
Scoring Fiberglass Strip to fit
contour of the windshield opening
Use adhesive 23-02-0127 on the just shaped stainless-steel strip and attach it to the fiberglass
strip. Use clamps to hold them in place. Allow 20 minutes flash off time for the adhesive.
Attaching the fiberglass strip to the stainless-steel strip
Page 12 of 16
Procedure 03-264
Apply adhesive 23-02-0127 to the stainless-steel strips, T03-3003, and attach it to the bottom of
the front cap. Use clamps to hold it in place.
Use clamps to hold extension in place on
the corners till adhesive dries
Repeat the process for the roadside windshield and remove all clamps after 20 minutes from the
application of adhesive.
4.6
Trimming Cap Extension:
Reinstall both windshields (See page 9 for full instructions). Lock calipers to 0.9. Use the top of
the windshields as you guide. Put one pointer on the top of the windshields and let the other
scribe a line on the front cap. Do this all the way across the front cap. Apply the lower edge of
the masking tape along scribed line. This will give a good guide for how much material needs to
be removed.
Calipers locked
at 0.9
Remove the windshields from the installed fencing and mark the scribed line with tape. Using D/A
sander remove the material up to the line scribed by the calipers.
Page 13 of 16
Procedure 03-264
Tape used to mark line where material is
removed
Using a DA sander to remove material to
tape line material
0.337-inch gap
Measure the gap between the top of the windshield and the bottom of the cap to ensure there is a
0.337-inch gap all the way across. If needed remove the windshield and trim until desired
clearance of 0.337-inch is reached. Once gap is reached remove both windshields and removed
gasket parts that where installed.
4.7
Install Fencing and Windshield
Apply 23-02-0122 primer along the outside grove of the fencing and allow 5 minutes flash off
time. Apply T03-3011 adhesive along the outside grove and install the fencing. Allow 20 minutes
for the adhesive to dry. Apply a lubricant, similar to MCI P/N: 21-7112-15, along the inside
surface of the fencing. Place the curbside windshield in the bottom groove of the fence and work
evenly up the right edge. After placing the right edge in the fence, put the top edge and then left
edge in the fence. Use fencing tool to help slide window into the fencing groove.
Repeat the process for the street side windshield.
Once windshield is installed install lacing in the fencing.
Page 14 of 16
Procedure 03-264
4.8
Testing and Validation
Start spraying water for 15-20 minutes on the windshield and look for any water leak inside the
coach. Look on the inside of the front cap at the marker lights and the 360 Camera if one is
installed.
Reinstall the opened trim pieces in the coach.
Page 15 of 16
Procedure 03-264
Install the wipers in such a way that the wiper blades are parallel to the middle section of the
fence and are 4 inches away from the edge. Tighten the nuts to 26-33 LB-FT.
Middle section of the fence
Install the washer hose
Clean the coach.
This procedure is now complete
End of Procedure
Page 16 of 16
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TSB/Document ID: P03-264
Replacement Service Bulletin Number:
MFR Communication Date: 2019-02-27
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: VISIBILITY:WINDSHIELD
MFR Component System:
MFR Component Subsystem:
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