A/C roof gasket replacement (with pics)

[exjay1]

OK.. so it was sunny and in the mid 60's today so I decide to go ahead and tackle the replacement of my A/C Coleman mach roof gasket. I wanted to document my repairs in hopes of showing others that this is infact a DIY job if you are able (and not scared) to get up on the roof. This job total took me about 2.5 hrs from start to finish, taking my time and the total cost for this repair was$25 for the gasket from the local Camping World. If you recall this thread http://www.jaycoowners.com/showthrea...fridge-amp-AC) which led to to discover my A/C gasket had failed during a camping trip in mid summer last year. OK, here we go..

Typical Coleman Mach roof top A/C unit (why do these fins break off so easy?? )



I removed the filter cover (two black plastic quick release screws) then the 4 spring loaded screws to start the shroud removal.



there is one of these retaining clips on each side that need to be removed along with the three phillips screws on the duct.

[exjay1]

now the shroud can be dropped and you will find the wiring harness as well as the AC mounting bolts



unclip the harness and disconnect the AC power wires.



I then started on removing the A/C mounting bolts (the ones that tend to work loose) with a ratchet.

[exjay1]

I then took a good look and relized how long these bolts really were so I upgraded to my shiny new Dewalt





with the 4 bolts removed the mounting bracket can be removed and put to the side.



To the roof now... I was advised by the guy at Camping World to use a blanket and plywood to set the A?C unit on to avoid tearing the rubber roof. Trust me there are some sharp edges/corners on this thing.

[exjay1]

next remove the 4 screws on top of the plastic cover to remove and set aside.



YUMMMY!



I took a tub of warm soapy water mixed with Simple Green to clean/prep for the the gasket then towel dried the area.

[exjay1]

OK next I removed the old gassket and could clearly see several reasons it had failed ( I believe it was doomed from the initial install at the factory )



I found some creases in the seal along with these 4 hard rubber 90 degree alignment spacers one on each side of the gasket to aid in the install from the factory. One of them had gotten caught under the seal and had flattened out (no bueno) thuse causing a gap in unit to gasket seal.

[exjay1]

Heres a look at the new gasket (14x14 standard opening) and after I cleaned the surface area I removed the sticky paper and installed in the underside of the A/C unit. The new one is about a good 1/4" thicker than whats left of the orig one.





I found a slight dip (lack of support) right where the romex cable comes out of so I cut a small piece of treated wood to fill in the gap. I found a old porch spindle with shim fit nicely in here and took care of the low spot.

[exjay1]

Next I sat the A/C unit over the opening then went inside and pushed up/centered the unit before reinstalling the mounting bracket. I used my ratchet to evenly snug everything up in an "X" pattern.





I tested my repair with some water all around the unit then checked inside for signs of leaks...found none.

[exjay1]

I reattatched the harness and the AC power cord to the shroud then installed. I found due to the addl thickness of the seal the three duct screws were now too short. I used some 1" screws of the same diameter to attatch then installed the two tab brackets (one on each side)



Finally installed the filter cover and called it done. Cheers!

[tnchuck100]

Thanks. This was very heplful.

[tinlizzie23]

Nice job, exjay1 ! Very informative, and great pics, too. You make it look simple and straight forward.

[amabee]

Excellent job of documenting that, VERY helpful.

[krackeer]

Looks like a great job on the install exjay! The pictures and procedure are well taken and documented. Overall a great job all the way around.

[Jagiven]

Very nice! I like the electrical tape on the wire nuts. I also do that when I install outlets.

Thank you,

[exjay1]

Yep, tape is just some added insurance.

[jdorant]

Nice write up. Thanks exjay!! How often would you say you should replace the gasket?

[lx22f/c]

Good write up and pics!!!
Thanks for taking the time!!!

[exjay1]

No problem. The only reason I changed mine was due to a leak and its a '05 model. Not sure how often to change it out as a maint item but just be sure to check the mounting bolts every season to ensure they havent worked loose over time.

[outofhere]

will definetly remember this Thanks

[Crabman]

Nice write up! I will have to bookmark this thread in case a how to question arises in the future!

[Rustic Eagle]

X2