NHTSA ID Number: 10164613
Manufacturer Communication Number: P03-270
TSB/Document Date: 2019-09-09
Summary
This Procedure instructs owners of affected model year 2018-2019 J4500 model coaches with windshield leaks to follow this procedure to isnpect the windshield and replace the fence if needed to prevent water leaks.
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TSB/Document ID: P03-270
Replacement Service Bulletin Number:
MFR Communication Date: 2019-07-30
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: VISIBILITY
MFR Component System:
MFR Component Subsystem:
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Procedure 03-270
J coach New Windshield Fence
Description:
Motor Coach Industries
("MCI") is instructing customers operating J Coach 2018-2019 with
windshield leaks to follow this procedure to inspect the windshield and replace the fence if
needed to prevent water leaks.
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. Position 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.
1 of 17
Procedure 03-270
1.0
Special Tools
Fence Tool (MCI P/N: P101)
6-inch steel ruler
6-inch steel ruler
2.0
Fence Tool
Windshield Inspection
To perform this procedure there must be an MCI approved windshield installed. Look for
an MCI logos on the windshield at the below-shown location. If the logos are not present
the windshield must be replaced by an MCI approved windshield before continuing.
MCI Logos
2 of 17
Procedure 03-270
3.0
Fence Engagement Inspection
Place masking tape along the top edge of the windshield fence on the front cap.
Tape placed at the top
edge of the fence
Remove the lacing from the top of the windshield fence
The lacing removed from the
top section of windshield
Insert the fence tool between the fence and front cap to release the fence from the cap.
Fence Tool
3 of 17
Procedure 03-270
Use the ruler to measure the engagement of the fence 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 top section of the fence.
The engagement measurement area
If no engagement is observed between the front cap and the fence measure the gap
between the bottom of the front cap and top of the fence.
No engagement
If the engagement is more than 0.25” perform Section 4.0.
If the engagement is less than 0.25” or if no engagement is observed perform Section
5.0.
4 of 17
Procedure 03-270
4.0
Sealing Windshield Fence
4.1
Material Requirement
Item
Part Number
QTY
U/M
Description
1
T03-3011
1
EA
Adhesive- Urethane, 3M 08609
2
23-02-0122
1
EA
Primer- Activator Teroson PU 8519p
4.2
Reapplying adhesive
Use fence tool to remove old sealant and dirt from between the front cap and the
windshield fence. Clean area with lacquer thinner to remove all debris and sealant.
Removing sealant and dirt
from between fence and front
cap across front windshield.
Apply primer 23-02-0122 between the fence and the front cap and allow to dry for 5
minutes.
Apply primer between fence and
front cap.
5 of 17
Procedure 03-270
Apply adhesive T03-3011 between the fence and the front cap. Apply enough to fill the
gap and allow the excess adhesive to run out on the tape.
Apply adhesive between fence
and front cap
Reinstall the lacing.
Lacing installed in fence
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
6 of 17
Procedure 03-270
5.0
Replace windshield fence
5.1 Material requirement
Item
Part Number
QTY
U/M
Description
1
T03-3046
1
EA
Fence- Windshield
2
T03-3011
1
EA
Adhesive- Urethane, 3M 08609
3
23-02-0122
1
EA
Primer- Activator Teroson PU 8519p
Additionally, four .188” dia Al rivets (MCI P/N: 19-13-295) are required if the coach is
equipped with 360 Camera.
5.2 Remove the existing fence
CAUTION
If the coach is equipped with wingman fusion camera, remove the two screws on
the camera cover. Save the screws and cover for later use.
Camera cover
Remove and
save the screws
7 of 17
Procedure 03-270
Disconnect the camera wiring and leave the camera attached to the windshield.
Disconnect
camera wiring
Remove and save the cap on the wiper arm of driver side windshield. Remove and save
the retaining nut. Repeat this on the other wiper arm. Disconnect the washer hose on the
wiper. Remove and save the wiper.
Repeat the above steps for the curbside windshield wiper.
Remove and save the retaining nut
Disconnect the washer hose
8 of 17
Procedure 03-270
Remove and save the fascia from the fence.
Remove and save the fascia
Remove and save the lacing from the fence.
Use the fence tool to separate the fence from the glass and spray lubricant, like soap
waster, between fence and windshield.
Remove and save the windshield on the driver side and curbside.
Remove and save
the windshield
9 of 17
Procedure 03-270
CAUTION
If the coach is equipped with wingman fusion camera, leave the camera attached
to the windshield.
Wingman fusion
camera
Remove fence from the front cap and discard.
Remove fence from the front cap
Clean all adhesive and sealant on the front cap using lacquer thinner.
Clean the front cap
10 of 17
Procedure 03-270
CAUTION
If the coach is equipped with 360 camera, remove and save the four screws
securing the top bracket of the camera.
Remove and save the four
screws
Remove the four rivets securing the bottom bracket of the camera.
Remove the four rivets
11 of 17
Procedure 03-270
Drill two .187” holes using 3/16” drill bit at .5”above the existing bottom holes as
shown below.
.187” dia new holes
.5”
Apply urethane to the fill the old four holes on the coach and install the bottom
bracket to the newly drilled holes using .188 dia Aluminum rivets, MCI P/N: 19-13295.
With the bracket as template drill the other two .187” dia holes on the front cap.
Secure the bracket using two .188 dia Aluminum rivets, MCI P/N: 19-13-295.
Install the rivets
Install the top bracket using existing hardware.
12 of 17
Procedure 03-270
5.3
Install new fence
Apply primer, MCI P/N: 23-02-0122, along the outside groove of the new fence, MCI P/N:
T03-3046, and allow 5 minutes flash off time. Apply a bead of urethane adhesive, MCI
P/N: T03-3011, all over the outside grove of the fence and install the fence, MCI P/N:
T03-3046.
Updated Fence T03-3046
Apply a lubricant, similar to MCI P/N: 21-7112-15, along the inside surface of the fence
and install driver side windshield. Use fence tool to help slide window into the fence
groove.
Use fence tool to slide window into
fence groove.
Repeat the process for the curbside windshield.
Place masking tape along the edge of the windshield fence on the front cap.
13 of 17
Procedure 03-270
Apply adhesive T03-3011 between fence and front cap along the top edge of the fence.
Apply enough that it fills the gap and allow the excess adhesive to run out on the tape.
Apply Urethane between fence and
front cap.
Excess adhesive coming out of fence
Take off the tape from the front cap.
Place the bottom of fascia in fence and use fence tool to run across the bottom to install
fascia as shown below.
Installing fascia
Cut the top right and left top corners the lacing at a 45-degree angle.
Corners cut at a 45-degree
angle
14 of 17
Procedure 03-270
Install the lacing.
Corners cut at a 45-degree
angle
Apply a bead of the adhesive T03-3011 across the top of the fence and then smoothen
it with a cloth.
Apply a small bead of adhesive
across the top of the fence
Let the adhesive dry for 2 hours.
15 of 17
Procedure 03-270
Install the wipers using retaining nuts 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.
Torque the nuts to 26-33 LB-FT.
4” from edge of the fence
Wiper installation
Install wiper arm cap.
Install wiper arm cap
16 of 17
Procedure 03-270
Install the washer hose and clean the coach.
Install washer hose
CAUTIONS
If the coach is equipped with wingman fusion camera, connect the wiring to the
camera attached to the windshield.
Connect camera
wiring
Install the camera cover using existing hardware.
Camera cover
Existing screws
End of the procedure
17 of 17
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