WORK INSTRUCTIONS
FRONT CAP LENS REPLACEMENT
WI NUMBER: WI-003-2024 REV-A Front Cap Lens Replacement REV-A
PRODUCT: Front Cap Lens
LABOR RATE: 0.3 hours per lens replaced

DATE: 8/21/24
Applies to:

This document refers to Brinkley front cap lens replacements.
Condition:
Brinkley RV has determined that under certain conditions the decorative light lens covers may peel, allowing
the possibility of water intrusion and damage to the LED light strips behind them.
Correction:
Brinkley RV has established a procedure to check, and if necessary replace the defective light lens covers.
Brinkley RV will, at no charge to the customer, pay to inspect and replace the front cap lenses as necessary.

DANGER
Because of the height of the front cap and the nature of the repair, use of a ladder is required. Follow
all ladder safety instructions posted on the ladder. It is required that professional technicians perform
the repair, and two people be used for this procedure. Failure to do so could result in injury or death.
In addition to standard shop tools, the following specialized tools are required:
1.
2.
3.
4.
5.

12’ or taller ladder (not shown)
Polystick
Clean, new microfiber wiping cloths
Hand held roller
Scotch Brite® pads (red)

2

3

4

5

Parts required (as needed per repair - Model Z FW - contact if other):
Part #

Description

QTY

101432
101367

LIGHT FRONT CAP BACKLIT ACCENT - DS UPPER
LIGHT FRONT CAP BACKLIT ACCENT - DS LOWER

1
1

101368
101431

LIGHT FRONT CAP BACKLIT ACCENT - ODS UPPER
LIGHT FRONT CAP BACKLIT ACCENT- ODS LOWER

1
1

101368

DOOR SIDE

OFF DOOR SIDE

101432

101367

101431

FRONT CAP LENSES

Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 2

ADVANCED CONTACT AND PRIOR AUTHORIZATION IS REQUIRED
CLAIM REIMBURSEMENT PROCESSING:
All reimbursement requests with completed work orders, including any freight expenses and photographs, should
be submitted via a claim in the Brinkley RV Dealer Portal. If you do not have access to our Portal, a claim can be
emailed to [email protected]
REQUIRED INFORMATION FOR IMMEDIATE REIMBURSEMENT PROCESSING INCLUDES:
1.
2.
3.
4.
5.
6.
7.
8.

The full 17 digit VIN;
The Retail Name if retail sold;
Dealer Name;
Dealer Address;
Dealer Phone Number;
Dealer Hourly Labor Rate;
Work Order detailing the work performed and labor time, and
A photograph of the repair in progress.

Reimbursement checks for claims submitted with all requested information are issued weekly.
SAFETY:
This document provides general instructions. Many variables can change the circumstances of any procedure,
i.e., the degree of difficulty involved in the service operation and the ability level of the individual performing the
operation. This document cannot begin to plot out procedures for every possibility, but will provide the general
instructions for effectively installing, removing or servicing the system. In the event the skill level required is
too advanced or the procedure too difficult, a certified technician should be consulted before performing the
necessary operation. Failure to correctly install, remove or service the system may result in voiding the warranty,
inflicting injury or even causing death.

DANGER
The “DANGER” symbol above indicates an imminent hazard that, if not avoided or handled correctly, will
result in death or serious injury.

WARNING
The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause death, serious
personal injury, severe product and/or property damage if not performed safely and within the parameters set
forth in this document.

CAUTION
The “CAUTION” symbol above is a sign that a procedure has a safety risk involved and may cause personal injury,
product and/or property damage if not performed safely and within the parameters set forth in this document.
Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 3

WORK INSTRUCTIONS:
1. READ AND UNDERSTAND ALL INSTRUCTIONS PRIOR TO BEGINNING WORK.
2. Inspect the front cap lenses for peeling. Inspect the ends and edges to determine if the adhesive has
failed and the lens is loose from the cap (Figure 1a - front cap reference, Figure 1b -“top” and Figure
1c - “Bottom”). The peeling condition should be presenting before proceeding or the lens should not be
replaced.

MODEL Z
FRONT CAP

PEELING
UPPER
LENS

Figure 1b

PEELING

LOWER
LENS

Figure 1a

Figure 1c

Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 4

3. Starting at the loose end, slowly peel the lens free of the cap (Figure 2).
4. Spray the residual adhesive left on the cap with an adhesive remover (Drummond Quick Peel Gel or
equivalent) (Figure 3).

Figure 2

Figure 3

5. Use a polystick to scrape off all of the adhesive where the original lens was attached (Figure 4a). Clean
the polystick with a clean microfiber cloth regularly (Figure 4b).

Figure 4a

Figure 4b

Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 5

6. Scuff the bonding surfaces lightly around the lens openings in the cap with a RED Scotch Brite pad to
improve adhesion (Figure 5a and Figure 5b).
7. Once all of the adhesive has been removed and surface scuffed, clean all of the surfaces thoroughly with
a mixture of 99% Isopropyl Alcohol and water, using new, clean microfiber cloths (Figure 6). Rotate
and replace the cloths regularly to make sure the bonding surface on the front cap is completely clean of
deposits and dry. Apply Isopropyl Alcohol 99% to each new cloth to clean the surface as necessary.

SCUFF MATING
SURFACES

SCOTCH BRITE
PAD (RED)

Figure 5b

Figure 5a

Figure 6

Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 6

8. Place the lens in the recess to make sure it is centered. Peel back 6” of the backer from the lens (Figure
7a). Start to apply the part at the top corner. Gradually remove the remaining backer as the lens gets
installed slowly and carefully. Press it firmly against the cap with your hands as you attach it (Figure 7b).

Figure 7a

Figure 7b

9. Use a hand roller to press the adhesive backing on the lens firmly in place; 15 lbs. of pressure is required
to activate the adhesive. (Figure 9).
NOTE: Be certain to press the entire lens firmly to maximize adhesive contact with the cap.
10. Peel the protecive coating off of the lens and inspect final result for seal (Figure 10).
11. Repair complete.

Figure 9

Figure 10
Work Instruction WI-003-2024 REV-A
Product: Front Cap Lens
Page 7