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Old 01-15-2018, 02:13 PM   #1
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Melbourne 24K on Mercedes Sprinter Chassis- couple issues

We have had our 2016 Melbourne for about 18 months. First real issue is a leak in the visor housing above the driverís head. The housing is original Sprinter equipment but we are thinking something about the Jayco installed overhang has a gap allowing rain to seep in. First trip to the dealer they couldnít find anything but when we had the same leak with a light rain we took it in and said keep it till you fix it. Has anyone else dealt with a similar leak? If it rains long enough the headliner along the visor housing will get soaked.
And I hate to even bring up the subject of the folding mattress again.... why wouldnít a memory foam mattress fold up enough to bring the slide in? Consumer ReClick image for larger version

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ID:	36716ports rates Costcoís Novafoam fairly high, and it costs around $600. We could trim the length if necessary. Costcoís return policy is so forgiving we are about ready to buy one and replace the uncomfortable thing it in now. We tried a foam topped but that didnít help enough.


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Old 01-15-2018, 02:54 PM   #2
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Its typical that a dealer can't fix certain problems since they don't know what to look for. I would follow up with an email to Jayco along with your VIN and ask them if this has been a problem with others and how did they fix the problem. Hopefully its a simple fix.
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Old 01-15-2018, 04:01 PM   #3
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It sounds like the seal that joins the MB Chassis and the cab-over part. I would assume there is some sort of rubber seal underneath that caulking strip but I don't know. I would also assume this rubber seal is the main weather seal for the cab and the caulking is just to dress it up. Even if they find and issue with the caulking I would question the integrity of the rubber seal if there is one. They should be able to duplicate it with a hose.


Don't get me started on the mattress. I think as long as the foam isn't too thick it would fold enough but how would you handle the step down on the mattress platform with a regular foam mattress? I have talked to but haven't gotten a quote from a company that would make a folding mattress with 2 foam thicknesses but I cant find the name right now. When I find it I will share it with you. DW says lets deal with it in case we decide to upgrade or until it wears out. It hasn't been too bad since I put the wood in there to fill the gap.
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Old 01-15-2018, 04:05 PM   #4
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It sounds like the seal that joins the MB Chassis and the cab-over part. I would assume there is some sort of rubber seal underneath that caulking strip but I don't know. I would also assume this rubber seal is the main weather seal for the cab and the caulking is just to dress it up. Even if they find and issue with the caulking I would question the integrity of the rubber seal if there is one. They should be able to duplicate it with a hose.


Don't get me started on the mattress. I think as long as the foam isn't too thick it would fold enough but how would you handle the step down on the mattress platform with a regular foam mattress? I have talked to but haven't gotten a quote from a company that would make a folding mattress with 2 foam thicknesses but I cant find the name right now. When I find it I will share it with you. DW says lets deal with it in case we decide to upgrade or until it wears out. It hasn't been too bad since I put the wood in there to fill the gap.


Perhaps we could use part of the topper we currently use and fill the gap? Hubby hasnít even noticed the gap 🤣 so I donít try to complain about it


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Old 01-15-2018, 11:19 PM   #5
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Mattress Drama..

I think I will get a 6" memory foam mattress and cut it to the correct length. Then build a lightweight platform for the lower section to keep the bed level. Also make it where it can be stored on the upper level when travelling. Being only 6" it should be able to fold up enough to bring the slide in. Also with my current 3" memory foam topper hopefully it will be comfortable enough. Anything would be an improvement over my new sinkhole...
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Old 01-16-2018, 05:52 AM   #6
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Hope you get leak fixed you do not want mold
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Old 01-16-2018, 07:44 AM   #7
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While the leak is visible at the visor, the water can be getting around the seal somewhere else and migrating to exit there. The water entry causing the leak you found could be above the visor or 10 feet away, further back in the unit, but the only place it can drip out is where you see it. Jayco will probably need to remove their top, try to locate a bad spot on the seal (rolled, cut, nicked, etc) and replace the section or entire seal.

Water will both enter and exit at the point of least resistance to flow. It could, in theory enter towards the back of the unit, flow along the seal (gasket) and exit in the front. The dealer shouldn't assume water is getting around the seal immediately above where you find it.

In all honestly, this is going to be hard to figure out and will take time, patience and experience to determine the entry point of the water and proper method of repair. Running a bead of silicon around the seam is not a permanent or correct fix. My guess is a nicked, cut or improperly applied seal further back in the vehicle. You might also have other seepage you haven't seen (hidden behind cabinets or hasn't soaked thru wall materials. And a water leak can lead to the metal seam of the truck body rusting and major damage down the road.

I would definitely contact Jayco and consider taking it to their repair center in Indiana to let them fix this, especially if your dealer cannot figure it out. Also, the dealer could remove the headliner to try to find the source. But again, a bead of silicon is not the best fix. Seal replacement, requiring top removal is.
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Old 01-16-2018, 08:59 AM   #8
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I would suggest looking at the marker lights. These are moved by jayco when they add the cap. A bad seal in these lights would run down the front cap and come out around the cap seal and original cab. Worth a quick inspection.


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Old 01-16-2018, 04:07 PM   #9
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Suggest you definitely contact Jayco, especially since your unit will be out of warranty soon. The factory told us that once it's on the books, they have to go beyond the warranty expiration date to find and fix the problem. We have an appointment in May to fix a water leak in our back bedroom slide. Worth the long trip to get it right. Our dealer flunked, and our warranty is out on May 18th! Jayco knows what the problem is, and we're confident that it will be fixed properly.

Honestly, we've said it before, but a couple of pool noodles in the bend of that mattress makes a world of difference, are easy to slip in when the mattress is extended and is a light-weight fix. It's a shame the mattress is such a screwy design, but this has worked for us. Pool noodles are $2 a piece - just give it a try.


As I like to say at the end of any of these posts, we've had our Melbourne for almost two years now, it now has 20,000 miles on it, and we love everything about it. In 2017 we were out for 4 months (not all at the same time). We've been all over the country, have plenty of power on every type of road, tow a Jeep behind us, and we've had minimal problems.
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Old 01-16-2018, 05:01 PM   #10
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I would suggest looking at the marker lights. These are moved by jayco when they add the cap. A bad seal in these lights would run down the front cap and come out around the cap seal and original cab. Worth a quick inspection.


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Thanks! What are marker lights? The rig is at the dealer right now so I canít go out and see what you perhaps are referring to. Good suggestion.


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