IK1600251 - Water Leaks Past Plastic Vapor Barrier Sheet in the Inner Cavity of the Cab ... Page 1 of 8

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CAB / SLEEPER / HOOD

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3/15/2019

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Steven
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IK1600251

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Title : Water Leaks Past Plastic Vapor Barrier Sheet in the Inner Cavity of the Cab Entry Door
Applies To : Any Cab Entry Door on LT, RH, HV, MV, LoneStar

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
11/12/2019 - Added options to repair the seal bead in addition to replacing the entire plastic barrier.
04/01/2019 - Initial Article Release.




DESCRIPTION
This document will guide the user through the repair and/or replacement of a plastic vapor barrier sheet seal on the cab entry
doors. This article discusses three options to complete the repair.
1. Repair the original seal bead with alcohol and heat gun.
2. Add a 2nd seal bead of Butyl Tape
3. Replace the entire vapor barrier.

SYMPTOM(s)
Water is found on cab floor near or at the threshold and/or floor just below the inside of a cab entry door. (may occur at any
door location)
Customer Observations or Concerns: Customer complains of wet flooring or water present at or near the entry threshold.
Water may be dripping from between the metal door panel and the interior door trim panel.
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s): N/A
There are no DTCs for this condition. FCAP does not apply for this condition.

SPECIAL TOOL(s) / SOFTWARE
Special tools are not needed or required for this service repair.
Tool Description

Tool Number

Comments Instructions

N/A

SERVICE PARTS INFORMATION

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Replacement plastic vapor barriers are available through the service parts warehouse. Please refer to the parts catalog for the
correct P/N needed based on the VIN and door position for the truck you are servicing.
Part Description

Part Number

Quantity
Required

Notes

Front Driver Cab Door - Plastic Water Shield

4053425C1

1

All Cabs

Left Rear Cab Door - Plastic Water Shield

3713540C2

1

Crew Cabs

Front Passenger Cab Door - Plastic Water Shield

4053426C1

1

All Cabs

Right Rear Cab Door ­ Plastic Water Shield

3713541C2

1

Crew Cabs

DIAGNOSTIC STEP(s)

Be sure to wear proper safety gear whenever servicing a vehicle

When working with running water to conduct leak testing; floors and other surfaces may
become slippery when wet. Use caution when working on or near wet surfaces.

Step Action
1

DIAGNOSTIC:
• Is water dripping or present at or near cab threshold?
• Is the Cab floor wet near the door?

Decision
Yes. Remove interior
trim door panel and
inspect the seal
bead holding the plastic
vapor barrier to the door
panel at each opening for
proper adhesion to metal
door panel. Water can be
poured at base of the
outer door window to
observe if water leaks
past seal bead at any
given location. (See
photos)
Note: The seal bead not
adhered to the metal
panel may be hard to see
so using water at time of
evaluation is preferred to
confirm seal integrity.
No. The vapor barrier is
properly sealed. No
further action is required.

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Step Inspection for seal bead adhesion to metal door panel
2

Procedure
1. Check for adhesion by
water leaking or dripping
2. Slightly lift plastic
vapor barrier all around
each sealed location to
check for adhesion to
metal door panel.
Note: If the areas of the
bead that are not
adhering are minor the
seal bead can be
cleaned and resealed or
an additional bead of
Butyl seal tape can be
added.

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REPAIR STEP(s)
Once it has been determined the vapor barrier seal is bad; there are three option to complete the repair:
1. Clean the area where the current seal bead is not making contact and water passes through with isopropyl alcohol. Slightly
heat the current seal bead to aprroximately 80 degrees F and roll it tight to the door with a wooden roller by appling
aprroximately 15PSI of pressure while rolling the seal bead. (Note: if the plastic vapor barrier is damaged, ripped, torn, or has a
hole use option 3 to replace the entire plastic sheet)
to replace the entire plastic sheet
2. Apply a bead of Butyl sealant similar in size to the current seal bead just along the outer edge of the current seal bead.
(making a double bead) Roll the Butyl sealant bead with a wooden roller to compress the seal so it bonds to both the plastic
barrier and the inner door panel. (Note: if the plastic vapor barrier is damaged, ripped, torn, or has a hole use option 3 to replace
the entire plastic sheet)

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Sample image of Butyl Sealing Tape
3. Replace the entire plastic vapor barrier with a new plastic vapor barrier from service parts. (If this option is used; follow the
procedure below)
The new barrier will come from the PDC with the sealant bead already adhered to the plastic sheet. Reference Fig 1.

Figure 1: Placement of New Vapor Barrier
REMOVAL PROCEDURE:
STEP 1: Remove the old barrier and all sealant residue. Using a heat gun to heat the vapor barrier sealant to ~80°F will aid in
removal.
STEP 2: Clean door panel with alcohol to promote proper adhesion of new seal bead. See Fig 2.

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Figure 2: Cleaning the Door Panel of Old Residue
INSTALLATION PROCEDURE:
STEP 1: Align the position of new plastic vapor barrier onto the door using the circular alignment features on the door panel.
(See Figures 3 & 4.)

Figure 3: Door Alignment Features for Placing Barrier Sheet in proper location.

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Figure 4: Plastic Vapor Barrier aligned and in place.
STEP 2: Installing new service part (Vapor Barrier Plastic Sheet) onto the door. The new part needs to be fully wetted to the
metal door panel by applying heat & pressure on the sealant bead with a roller while it is still heated. Heat to ~80°F. (See Figure
5.)

Figure 5: Rolling new sealant to door panel for proper adhesion

WARRANTY INFORMATION
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

STANDARD REPAIR TIME(S)
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
Note: At the time of publication, there was not a specific SRT for this repair. Refer to LT-16-5345A, Steps 1 thru 14 and steps
24 thru 32 for disassembly & reassembly.

OTHER RESOURCES

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