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Old 12-09-2022, 03:08 PM   #1
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Poorly fitting Mountain Aire headlights

While checking the generator with the front cap extended, I noticed quite a bit of daylight between the headlight assemblies and the front cap of my 2022 Mountain Aire 4018. The driver's side headlight assembly is a worse fit. As seen in the picture below, I'm able to get my index finger through the side of the gap without a problem. Behind this gap are several electrical components and connections which seem to me to be at risk due to water intrusion. Has anyone else noticed this and, if so, how was it managed? How concerned should I be?


1st picture was taken from the back of the front cap looking forward and shows the back of the driver's side headlight.
2nd picture shows my index finger in the gap for scale.
3rd picture shows the portions of the coach directly behind the headlight.
4th picture shows the smaller gap around the passenger side headlight.

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2022 Mountain Aire 4018
2017 Jeep Cherokee Overland
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Old 12-09-2022, 03:22 PM   #2
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Notice how many attachment points there are and that they all are slotted.
Also note how neatly the surrounding wires are arranged.
If GOD had not invented Zip Ties, you would be in a world of hurt.

Welcome to the wonderful world of RV's.

If you are not a plumber, electrician, carpenter, mechanic now, you will become one soon.
However, some folks just carry 3 plastic wrenches. M/C, Visa, Am Exp.

It's up to you to choose..........

Mike in Colorado
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Old 12-10-2022, 06:44 AM   #3
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Quote:
Originally Posted by joedep View Post
While checking the generator with the front cap extended, I noticed quite a bit of daylight between the headlight assemblies and the front cap of my 2022 Mountain Aire 4018. The driver's side headlight assembly is a worse fit. As seen in the picture below, I'm able to get my index finger through the side of the gap without a problem. Behind this gap are several electrical components and connections which seem to me to be at risk due to water intrusion. Has anyone else noticed this and, if so, how was it managed? How concerned should I be?




1st picture was taken from the back of the front cap looking forward and shows the back of the driver's side headlight.
2nd picture shows my index finger in the gap for scale.
3rd picture shows the portions of the coach directly behind the headlight.
4th picture shows the smaller gap around the passenger side headlight.

-----------
2022 Mountain Aire 4018
2017 Jeep Cherokee Overland
Seem that one or more of the retention clips are missing. Recommend a call to your Newmar coach CSR or better still your dealer.
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Old 12-10-2022, 07:41 AM   #4
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Quote:
Originally Posted by Flyer15015 View Post
Notice how many attachment points there are and that they all are slotted.
Also note how neatly the surrounding wires are arranged.
If GOD had not invented Zip Ties, you would be in a world of hurt.

Welcome to the wonderful world of RV's.

If you are not a plumber, electrician, carpenter, mechanic now, you will become one soon.
However, some folks just carry 3 plastic wrenches. M/C, Visa, Am Exp.

It's up to you to choose..........

Mike in Colorado
Thanks for your thoughts. Fortunately, there is another option. IMHO, the front cap was manufactured for a different shaped headlight. Manufacturing defects are still covered under Newmar's 1 year warranty, so I'll try that route first.
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Old 12-10-2022, 07:53 AM   #5
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Originally Posted by Clemson View Post
Seem that one or more of the retention clips are missing. Recommend a call to your Newmar coach CSR or better still your dealer.
Thanks for the suggestions. I'll try the dealer first.

Unfortunately, I'm skeptical the largest gap(s) can be closed with a screwdriver and/or clips since both the headlight assembly and front cap are quite rigid/inflexible. It seems likely that an attempt to pull them tightly together would result in damage to one or the other. If the coach wasn't still under warranty, I'd probably DIY a fix with waterproofing foam or tape.

I'm really curious. Is my observation just a one-off or have others found the same thing on their 2022 MAs?
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Old 12-10-2022, 10:06 AM   #6
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FLSteve

Hopefully FLSteve can chime in here as he has a 22 4118 and is very knowledgeable.
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