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Windshield washer fluid fitting on passenger side

May 28, 2012, 12:43:35 pm

This is a reprise of an earlier question on the same topic. I am trying to replace a broken fluid fitting that passes through the front of the coach to supply washer fluid to the wiper arm. I tried repairing it, but was unsuccessful.

I followed Brett's instructions (thanks!) and removed the long thwartship dash cover to reveal the hole by the windshield wiper motor in the plywood underneath. However, the washer fitting is so far to the right of the hole I can barely touch the fitting with my fingers. The 1/2" plywood panel underneath the dash cover does not appear to be readily removable.

Since the fitting is directly in front of the automotive electrical panel at the stair well, I tried dismounting it to see if I could get access that way. Removing the screws did not allow me to move the panel enough to get at the fitting.

I guess I can cut another hole in the 1/2 plywood directly above the fitting, but thought someone might have a better solution. Anyone been in there before?

Thanks

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Re: Windshield washer fluid fitting on passenger side

Reply #1 – May 28, 2012, 03:45:04 pm

I looked at that when I had the dash cover out for recovering, and it would be easy to make access with a 3' or 4" hole saw in the right place.  I would almost certainly do that, since removing all the front pieces is not fun (I've done it...).  Of course you need to check to see locations of wires, vent ducts and the steel support tubing.

FWIW - here's what our front dash looks like without all the upholstered pieces.  Yours is probably quite similar.

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Re: Windshield washer fluid fitting on passenger side

Reply #2 – May 28, 2012, 05:09:18 pm

Dave,
Is the long upholstered piece where the defrost vents are just held on by velcro?
Peter

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Re: Windshield washer fluid fitting on passenger side

Reply #3 – May 28, 2012, 10:30:20 pm

Yes.

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Re: Windshield washer fluid fitting on passenger side

Reply #4 – May 29, 2012, 12:21:28 am

Yep, just held in with Velcro, but you may have to remove the front right horizontal piece that has the grab handle on it (remove the elec panel cover to access the screws) and the right vertical piece next to the windshield to get enough clearance to lift the dash cover out.  Both are easy to get out, but you will really appreciate a power screwdriver for all the screws around the grab handle...

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Re: Windshield washer fluid fitting on passenger side

Reply #5 – May 29, 2012, 12:46:49 am

Dave, I heard that the top vinyl covered panels are held in place with Velcro, but did not realize that removing them did not open up the dash. I didn't know there was a permanent wood base to our dash. Thanks for the naked photo. Barry & Cindy

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Re: Windshield washer fluid fitting on passenger side

Reply #6 – May 29, 2012, 10:47:56 am

Good morning Bob,  I talked to Drew in service ( Foretravel)  and he suggested you cut a hole behind the wiper nut.
He said it would not hurt a thing.   
Good luck 

Ben
Bonnie
Tex 1999 in service bay

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Re: Windshield washer fluid fitting on passenger side

Reply #7 – May 29, 2012, 07:32:11 pm

Dave,

Last year, we had our door & door frame vinyl recovered with the same Ultra-Leather we put on our new FlexSteel chairs. We found we could not remove our door frame without removing the front right horizontal piece you mentioned, so we now know about all the wood screws that secure the grab handle. And my battery screwdriver is always a big help.

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Re: Windshield washer fluid fitting on passenger side

Reply #8 – May 30, 2012, 10:21:51 am

Dave,

Looking at your dash pic, I have a Q.  Does this plywood piece appear to be adhesive bonded to the front cap fiberglass? 

Thanks, Chuck

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Re: Windshield washer fluid fitting on passenger side

Reply #9 – May 30, 2012, 01:09:35 pm

No, the plywood is only attached with Velcro.  Make sure you do everything Dave says before pulling up the plywood.  Otherwise you could crack one of the windshields.  Don't ask!

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Re: Windshield washer fluid fitting on passenger side

Reply #10 – May 30, 2012, 07:40:25 pm

Brett,

When you said to follow Dave's instructions, are you refering to removing the grab bar mount?

Dave did not mention anything special to prevent damage to windshield, so I am not sure what to not do.

What instructions should we follow?

Thanks,
Barry

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Re: Windshield washer fluid fitting on passenger side

Reply #11 – May 31, 2012, 01:47:16 am

Not sure which plywood piece you're referring to, but the thin (1/4") plywood dash cover piece that is covered in vinyl is only held down to the underlying 3/4" plywood piece by velcro, and not attached to the windshield at all in our coach.  In fact the edge sits almost below the windshield gasket.    I don't think there is any danger to the windshield if you don't force the removal of the dash cover and lift the rear edge first.

The plywood of the cover is very thin and can be broken at the narrow section where the instrument cover is, so good to be careful taking it out.  Once it's out, it's easy to patch underneath...

The only reason that you have to remove the  the grab bar-piece and the right vertical vinyl-covered piece, is that they may overlap the rear edge and side of the dash cover piece.  Just try lifting the rear edge of the dash cover piece, and bent it gently in the center (need to lift the instrument cover) to clear the right side piece.  If it is held down by one of the mentioned pieces, you'll need to remove it.  Work something thin under the dash cover piece if necessary to release it from the velcro (although in ours, the velcro glue was happy to release...)

Try removing the grab bar piece first, and then you may be able to work the right edge of the dash cover out without removing the right vertical piece. 

The right side vertical piece you may have to remove is the small flat piece (about 2" wide x 1/4" thick x 38" tall, and is screwed onto the front of the long corner piece on the front side of the door (you don't need to remove that piece.)  A right-angle screwdriver is necessary (unless you happen to have the windshield out...)  If you still have the pleated windshield screens, that piece is the one the right side half screen attaches to.  Depending on the tightness of Foretravel's carpentry, you might also have to remove the left side vertical trim piece, but that comes off easily with 3 screws under the vinyl-covered caps.  If you have MCD front shades (as we do), both sides will have to come out, since the shade channels overlap the dash cover. 

Now the underlying 3/4" plywood piece visible in the photo may well be bonded to the front cap below the window gasket (I don't remember), and it is attached to the steel tubing framework, but no reason you would ever have to remove that piece.

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Re: Windshield washer fluid fitting on passenger side

Reply #12 – May 31, 2012, 07:12:22 am

Barry,

I meant don't try to remove the dash without removing the grab bar and vertical side panels.  I got mine out without doing that, put went I installed it, the windshield cracked a short time later.  Just don't take any short cuts.

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Re: Windshield washer fluid fitting on passenger side

Reply #13 – May 31, 2012, 10:39:11 pm

Many thanks to Dave K, Brett H and Ben H for supplying information that made this project straightforward.

At the risk of belaboring the info provided by these folks, here are the steps I followed to remove the horizontal covered/padded dash and cut holes to access and replace the passenger-side, through-bulkhead windshield wiper nozzle:

Remove the inside windshield shades by lifting up when they are in the fully retracted position. Then remove three padded screw covers and three screws on each side and remove vertical trim pieces (2) at extreme sides of the windshield.

Remove the dash instrument panel cover by lifting up and removing 8 screws from the two hinges. Square drive ratchet helps here as space is a bit restricted. Then remove the "Doghouse" dash cover by lifting up and removing 8 screws from the hinges. Take care here as dropping a screw into the maze of wiring can be frustrating.

Remove the grab handle at the entry steps by removing the plastic covers (2) and removing two Phillips screws. Gently pull out the bottom of the vertical panel covering the automotive electrical panel at the entry steps, drop it down and rest it on the floor. Then remove (seven in my case) long screws and remove the horizontal trim piece.

Finally, starting at the driver's side, gently pull up and remove the 1/4" vinyl-covered plywood dash cover. This reveals a piece of 1/2" fiberglass-covered (top and bottom) plywood that extends the full width of the dash.

In my case there was no hole in the 1/2" plywood to access the nozzle. So I went outside and marked the position of the passenger side nozzle with a piece of tape on the windshield. Then I cut two overlapping 2 1/4" holes in the plywood about 1 1/2" aft of the windshield. I slightly favored an inboard position in case I ever needed to work on the wiper itself. Once the holes were cut and trimmed a bit, it was easy to remove washer hose and the nozzle nut (9/16") to replace the nozzle. Be aware that the Denso nozzles are plastic and the barbed end is easily broken at the base of the nozzle. I prefer a metal nozzle, but so far, for the ones I have found at bus supply companies, the threaded ends are too short for the thickness of my front bulkhead.

Reassembly is simply the reverse of the removal process.

Here are some photos of the process. Hopefully the pictures and text will match up.

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Re: Windshield washer fluid fitting on passenger side

Reply #14 – June 01, 2012, 09:14:20 am

Howdy Bob,
    Thanks for this great write-up with very nice photos..I'll be bookmarking this one for future reference.

Dave Abel

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