Solution K23033111
Tuesday, November 5, 2019 4:53:31 PM CET

** SOLUTION **
Title

Volvo Chassis - Cab Roof Leaks, Water Intrusion At Roof Joints; Repair Instructions
And Information; Supplement To FSB 812-002, Cab Roof Leak Repair - VN Models
740 And 760 ONLY, Model Year 2018 And Newer

Volvo Models
VN , VNL , VNR

Volvo Model

** SOLUTION **
Instructions and information concerning repairs for cab roof leaks.

Cause

Note: Information is subject to change without notice. Illustrations are used for reference
only and may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
Solution

The precautions and guidelines in Service Information, group 80, "General Safety Practices, Cab" must
be read and understood before performing this procedure. If further training or certification is required,
a supervisor should be consulted prior to proceeding with the steps below.

Do not attempt to repair or service this vehicle without having sufficient training, the correct
service literature and the proper tools. Failure to follow this could make the vehicle unsafe and
lead to serious personal injury or death.

Tools And Supplies
Tool

Description

J-41764

Installation Rope

J-41765

Suction Cup

J-2189-32

Plastic Adjustment Knife

Qty

Description

2

Fusor® 141 Clear Bonding Adhesive

1+ (As needed)

Fusor® 803DTM Sealant (Black)

4

Fusor® 401 Cartridge Mixing Tips

1

Masking Tape

To purchase products or for application information on the Fusor® products, call 1–877–ASK-LORD
(275-5673). Also refer to the Lord Corporation website at www.lord.com.

Windshield Removal

It is recommended that scaffolding or other suitable work platform be used when performing
this procedure. If scaffolding or suitable substitute is not available, extreme care must be taken
to ensure slippery surfaces are cleaned or avoided. Proper footwear must be used. Failure to do
so may result in a fall causing serious personal injury.

1. Open the hood.
2. Remove the wiper arm retaining nut and the wiper arm.

3. Place the suction cups (J–41765) on the windshield with the handles turned up and apply suction.
- The cups should be placed above the mid-line of the windshield with the handles pointing up.

4. Start by pressing out a top corner of the windshield by putting the foot on the inside and pressing
steadily until the molding starts moving out. At the same time outside of the cab, begin working the

molding loose. Push and pull the windshield the rest of the way out.
5. Remove the old molding from the windshield. Inspect it for any damage. Look for dry-rot, cracks
and cuts.
Note: The windshield drip molding is not a separate component, it is an integral part of the
windshield molding.
- If the molding is intact, clean it for reuse.
- If wear or damage is found, replace as is necessary.

Resealing Procedure
Note: All repairs require roof and cab to be at least 16° C (60° F). If necessary bring truck inside and
let it warm up several hours before beginning repair.
Note: When the roof is installed at the factory the adhesive bonding areas are located at the upper edge
on the cab structure not the lower edge of the roof, this leaves voids along both sides of the cab but not
in the front or rear. When bonding the lower edge of the roof to the cab with Fusor®, do not attempt
to completely fill the void areas along the sides. A diagram of the voids can be seen below:

1. Disconnect all cables from the negative (ground) battery terminals to prevent personal injury from
electrical shock and prevent damage to electrical components.
2. Apply the parking brake.

3. Remove the external sun visor and fairing attached to the fiberglass roof.
4. Inspect the seams where the fiberglass roof is bonded together for any cracks.
5. Clean the entire joint area between the roof and the cab around the front and down both sides to the
B Pillars behind driver and passenger doors. Use a damp cloth to remove any dirt, follow with an
alcohol wipe and a dry cloth to remove any moisture.
6. Apply masking tape above and below the joint to keep sealant from getting on painted surfaces.
Above the windshield, apply tape all the way to the rubber seal under the roof’s edge. See the picture
below for correct placement:

7. Using Fusor® 141 Clear Adhesive, start sealing at one B pillar, working around the perimeter to the
other B pillar in one fluid motion. Make sure there are no gaps in the sealer.
- Note: If there is a gap at the front of the roof between the cab and the roof center panel of more
than 10 mm (0.4 in). Apply Fusor® 803DTM sealer to fill the entire gap area and spread it out
evenly and smoothly with a putty knife. Be careful not to let the sealant drip onto the windshield.
When finished, the sealer should form a smooth black ledge between the roof and cab with no voids.

8. Remove the masking tape as soon as the sealer application is completed.
9. Reconnect all previously removed cables to the negative (ground) battery terminals.

Windshield Installation
1. Install the windshield molding onto the windshield.
2. Make a loop in one end of installation rope (J–41764) on one side of the windshield and begin
inserting the rope into the groove in the molding. Continue to push the rope into the groove around the
windshield until the rope ends meet at the other side. Overlap the ends as shown below.
- Note: To help with the installation, presoak the installation rope in soapy water.

3. Clean the window opening in the cab.

4. Place the suction cups (J–41765) on the outside of the windshield towards the outer edges and with
the handles turned upward. Apply suction. Lift the windshield up into position in the window opening.

5. Press the windshield against the cab opening. From the inside, begin pulling the rope. This works
the inner edge of the molding over the body flange. Start on one side, move to the other side and do top
and bottom last.

6. Using the plastic knife, carefully work the outside of the rubber molding completely over the body
flange.

7. Clean the windshield.
8. Install the wiper arms.
- Tighten the wiper arm nuts to a torque of 23 ± 3 Nm (17 ± 2 ft-lb). Connect the windshield
washer hoses.
9. Water test and check for leaks.
- Direct a low pressure stream of water from the top of the cab so water runs in an even stream
across the windshield. If any leak develops, check the seal for proper installation. If the seal is
installed correctly, run a seal bead between the seal and body.

Warranty Information
This repair may be eligible for reimbursement if a product failure was
experienced within time and mileage limits of the applicable Warranty coverage.
Reimbursement is obtained via the normal claim handling process.

Claim Type (used only when uploading from the Dealer Bus.
Sys.)

W

Labor Code
8126-16-09Primary Labor Code

01
3.4 hrs

Causal Part
Campaign code

FSB812-002

Solution visibility

Dealer distribution

N/A

Function(s)/component(s) affected
Function affected

Body and Trim , FSB

Function Group
Function Group

812 roof, windscreen and rear window frame

Customer effect
Main customer effect

fluid , visual appearance

Fluid problem

leak

Fluid implicated

Water

Visual appearance

leaking

Conditions
Vehicle operating mode
Frequency of occurrence of
problem
Weather conditions

when driving , when stationary
random
wet

Administration
Author

RU4469V, UT0783V

Dealer ID

RU4469V

Last modified by

RU4469V

Creation date

16-05-2018 18:05

Date of last update

29-10-2019 16:10

Status

Published

UNCONTROLLED COPY. Printed document is for temporary use only and should not be retained.