Kenworth W900 Long Hood Spring Pocket Repair Kit

Step 1

Using 1001-4 EcoPrep™ plastic cleaner, clean the spring hood pocket and the surrounding area where the reinforcing plate will be attached.

Step 2

Using the trim saw, cut away the edge of the hood spring pocket to allow the casting center to clear the hood.

Leave as much material as possible to keep the maximum bond area between the hood and the casting.

Step 3

Test fit the casting to the pocket and trace around the perimeter with a permanent marker. Cut away as much of the flange as needed to make the reinforcement fit all the way down into the pocket.

Step 4

Grind the area where the casting will be bonded with a 50 grit or coarser Roloc™ disc. Be sure all paint is removed inside the traced outline.

Step 5

THOROUGHLY HAND SAND the inside of the pockets anywhere the Roloc™ disc couldn’t reach with 60 grit or coarser sandpaper, make sure all paint is removed and the area is thoroughly roughened. Roughen all remaining surfaces to be bonded with 60 grit or coarser sandpaper.

Step 6

Clean the outside of the aluminum castings with 1001-4 Eco-Prep™ plastic cleaner or 1000-A Super Prep™ plastic cleaner.

Step 7

Thoroughly grind the bonding surface with a 50 grit Roloc™ disc to make it receptive to 2510 PlastiFix© adhesive.

Step 8

Test fit the casting and push it firmly into place. It should be in contact with the hood everywhere, however short gaps up to approximately 1/8” are acceptable but will need to be completely filled with PlastiFix© adhesive. If it doesn’t sit all the way down into the pocket, sand or grind the interfering areas of the hood or casting and test fit again. Repeat this until you’re confident the casting is bottomed out in the pocket.

Step 9

Using a permanent marker or a drill, mark the hole locations for the screws. (Marking with a drill shown.)

Step 10

Drill all seven (7) hole locations and remove the dust using compressed air or a cloth dampened with EcoPrep™ or Super Prep™ plastic cleaner. Make sure the area is completely dry before proceeding.

Step 11

Apply a generous layer of 2510 PlastiFix© evenly over the mating surface of the hood.

Spread the adhesive with a body spreader and work it into the sanding scratches. Work quickly because the adhesive working time is 15 minutes at 68°F (20°C).

Step 12

Immediately apply a generous layer of 2510 PlastiFix© over the mating surface of the casting. Apply the adhesive in rows to allow air to escape when pressing the parts together. There should be enough adhesive applied to the casting to cause some of it to squeeze out when the casting is screwed into place.

Step 13

Install the casting and secure it into position loosely with the included screws. DO NOT TIGHTEN the screws until all screws are in place and the casting is seated into the pocket correctly. Hand tighten the screws only until firmly snug. If the screws are installed too tightly, too much adhesive will squeeze out, starving the joint and weakening the bond.

Step 14

Fill any gaps with more PlastiFix©.

Step 15

Wipe up any excess adhesive.

Step 16

When fully cured, install the OEM eyebolts into the casting with low or medium strength threadlocker to prevent galvanic corrosion between the eyebolt and the casting.

Use a nut and lockwasher on the inside of the pocket to lock the eyebolt into position.

Step 17

Connect the springs only after the PlastiFix© has fully cured. Maximum strength is achieved in 24 hours at 68°F (20°C). PlastiFix® full-cure can be accelerated with GENTLE heat AFTER the initial cure. The adhesive should feel very hard before applying gentle heat. DO NOT EXCEED 130°F (54°C) surface temperature while accelerating the cure; higher temps may reduce the strength of the adhesive.

Step 18

Connect the springs to the eyebolt.