Roof Assembly – Plywood Decking Replacement
Publication Date:

Bulletin Type:

SRP

Bulletin #(s):

24-005

Make(s):

Job Code(s):

If affected unit has warranty
remaining, submit your claim
following the normal process

Model(s):

Flat Rate(s):

Incident:
Affected Units:

Parts List:

Misc. Tools & Supplies:

Model Year(s):

March 2024
Entegra Coach
Aspire, Anthem,
Cornerstone
2022-2024

Cracking in roof assembly causing leaks
2022-2024 Entegra Coach Aspire, Anthem and Cornerstone units
450 SF - INSULATION,15X67' R-7 PINK UNFACED (Purchase Locally)
4 Tubes - SEALANT,SIKAFLEX BLK 268 ULTRAFAST 10.5OZ (Jayco Part #0214205)
10 Sheets - PLYWOOD,12MMX48.00X90.25 CPC ARAUCO (Purchase Locally)
75 FT - TAPE,BUTYL .13X.75X30' W/80% BUTYL (Jayco Part #0196164)
16 FT - TAPE,BUTYL .13X.50X30' GRA (Jayco Part #0207420)
7 EA - TRIM,AL 144.00 MF EXTRN (Jayco Part #0164297)
2.5 Gallons - ADHESIVE,VNL RF 5GAL (Purchase Locally)
300 SF - FIBERGLASS,RF 90.50X700' G3 PW #8016 W/O FILM (Jayco Part #0246131)
72 EA - SILICONE,NUFLEX #311 BLK SELF LVLG TUBE (Jayco Part #0260646)
Screwgun with Square Bit
Small Flathead Screwdriver
Pry Tool



Please read the following instructions thoroughly before starting the repair. If you have any questions,
contact Jayco customer service department.



This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.

!

WARNING

!

Electrical current from power, telephone, and communication cables is hazardous.
To avoid a shock hazard, make sure the 12V Main Disconnect Switch and Inverter
are OFF and disconnect the batteries before performing the repairs.

24-005_SRP Roof Assembly Plywood Decking

March 2024

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1. Disconnect and remove all necessary awnings.
2. Disconnect and remove all necessary components from the roof. (Figure1) Items may include:
A. Starlink
B. Vent Fans
C. Air Conditioners
D. Solar Panels
E. Skylights
F. Satellite Dish
G. Antennas

Fig. 1

3. Remove necessary seal to access the trim along the front cap, rear cap and sides of roof.
4. Using screwgun with square bit, remove and discard all perimeter trim.

Fig. 2
5. Remove and discard attached fiberglass panel from the plywood. (Figure 3)
6. With a pry tool, loosen the radius roof cap from the plywood. (Figure 3)

Fig. 3
7. With the roof decking exposed (Figure 4):
A. Number the decking pieces from front to back.
B. Measure width and any holes/cutouts of each deck piece.
C. Mark the seam locations.
10

9

8

7

24-005_SRP Roof Assembly Plywood Decking

6

5
March 2024

4

3

2

1
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Fig. 4
8. Using a screwgun with square bit, remove all deck panels. (Figure 5)

Fig. 5
9. With the 3/8” decking removed:
A. Verify the decking seam location offsets the interior ceiling board seams.
NOTE: These must be staggered and/or should not land on top of each other.
NOTE: Roof decking seams must land on top of roof rafter.
B. Cut the replacement ½” plywood decking including current or updated width of decking panels.
C. Mark and cut the openings using the previous measurements (Step 7).
10. Pulling back the ASTFL reflective back, inspect and replace any wet R-7 pink insulation. (Figure 6)

Fig. 6

11. Shimming the Front and Rear Cap (Figure 7):
A. Remove all fasteners from the front and rear caps to allow the front 3/8” plywood to be lifted.
B. With the use of a prying tool, slide the 1/8 luan shim under the 3/8” plywood – both front and rear.

24-005_SRP Roof Assembly Plywood Decking

March 2024

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1/8” Luan Shim

Fig. 7

3/8” Plywood
1/8” Luan Shim

3/8” Plywood and 1/8“
Shim must be flush

12. Installing roof decking to the second A/C opening (Figure 8):
A. Starting with the front (#1) piece of 1/2” plywood decking, align with the stackup (3/8” plywood
with 1/8” luan shim) and center under the radius roof cap.
B. Using a screw-gun with square bit, secure perimeter of the 1/2” plywood panel every 8-12 inches.
The panel will be secured to every truss within the panel section every 8-12 inches.
C. Repeat step 12 for every deck panel until the second A/C opening.

Fig. 8

13. Starting with the ½” deck panel with the 2nd A/C opening, apply Sika to every truss until the truss behind the
3rd (rear) A/C. (Figure 9)
24-005_SRP Roof Assembly Plywood Decking

March 2024

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Fig. 9

14. With the Sika installed, continue securing the remaining panels. Using a screwgun with square bit, secure
perimeter of the 1/2” plywood panel every 8-12 inches. The panel will be secured to every truss within the
panel section every 8-12 inches. (Figure 10)

Fig. 10

15. With staple gun, secure the radius roof cap down to new ½” plywood decking from front to back.

Fig. 11

16. Apply 3/4” wide butyl tape along both sides on top of the roof radius cap. (Figure 12)

24-005_SRP Roof Assembly Plywood Decking

March 2024

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Fig. 12
17. Installing the exterior fiberglass
A. Roll out new piece of fiberglass panel from front to rear.
B. Pull back the forward half of the fiberglass panel and apply adhesive – pour out the adhesive and
roll out with uniform coverage. (Figure 13)
C. Pull back the rear half of the fiberglass panel and apply adhesive - pour out the adhesive and roll
out with uniform coverage. (Figure 14)
D. From the middle toward the rear, roll out the rearward section of the fiberglass panel.

Fig. 13

Fig. 14
18. Lift the edge of the fiberglass panel and remove the top side paper from the butyl tape on both sides.
24-005_SRP Roof Assembly Plywood Decking

March 2024

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19. Using a prying tool, slide the fiberglass panel between the front cap and the 3/8” plywood. Repeat for rear
cap. (Figure 15)

Fig. 15

20. Apply 3/4" wide butyl tape along each side on top of the fiberglass panel. (Figure 16)

Fig. 16
21. Installing aluminum trim to sides of unit (Figure 17):
A. Remove top paper from the butyl tape.
B. With a screwgun, secure aluminum trim. NOTE: Every hole in trim should have a fastener.

Fig. 17

24-005_SRP Roof Assembly Plywood Decking

March 2024

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22. Installing aluminum trim to the front and rear of unit (Figure 18):
A. Apply ½” wide butyl tape along the front and rear edge
of the fiberglass panel.
B. Remove top paper from the butyl tape.
C. With a screwgun, secure aluminum trim. NOTE: Every
hole in trim should have a fastener.

Fig. 18

23. Cut/route all holes in the fiberglass panel and pull any necessary
electrical.
NOTE: A screw should be inserted into the center of the
larger openings for vent, skylight and/or Air Conditioner.
When routing the opening, the screw must be held so
that a clean perimeter cut occurs. Allowing the fiberglass
to hang can cause cracks to start.
24. Apply self-leveling adhesive on top of the perimeter trim.
25. Connect and re-install all previously removed components.

Jayco’s sole obligation under our limited warranty is to repair or replace defective materials and/or workmanship deemed our responsibility as determined
by Jayco in our sole discretion. Jayco reserves the right to use new and/or remanufactured parts or materials of similar quality to complete any work, and to
make parts and/or design changes as appropriate without notice to anyone. Jayco designs and/or materials changes are done without obligation to
incorporate such changes in previously manufactured product. Jayco makes every reasonable effort to ensure field remedies will not adversely affect
performance and/or safety of the unit. This field remedy is not intended to extend to future performance of this RV, or any of its materials, components or
parts beyond the standard warranty period. The RV owner’s obligation to notify Jayco, or one of its independent, authorized dealers, of a claimed defect
does not modify any obligation placed on the RV owner to contact Jayco directly when attempting to pursue remedies under state or federal law.
.

903 South Main Street • P.O. Box 460 • Middlebury, IN 46540

24-005_SRP Roof Assembly Plywood Decking

March 2024

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