[scottz]

I worked up the energy today to pull the rear AC off and take a look at it. Same problem as the front. The unit was not aligned with the holes in the roof; it was about 1 3/4" too far forward. I had to re-position it to get all the gaskets to line up.

I found an easy way to check for this problem without pulling the unit off the roof. Pull the cover off, then pull off the foam that covers the squirrel cage blower and duct work. You can put your hand down and feel if the seals of the cold side and return side match the holes in the roof and proceed from there.

Photo 1 shows how the unit was misaligned (and after I re-taped the duct work). The blue tape closest to the camera is where the seals were; the blue tape closest to the cutouts is where the seals should be.

Photo 2 is shows the cutouts and the bottom of the AC unit.

Photo 3 shows the top of the AC unit with the foam cover removed. You can see the cold air duct below the squirrel cage blower; the return duct has all the wiring in it.

Photo 4 shows how far I had to move it. I used a little Dicor to seal up the old holes.

One note of caution: If you pull the AC unit off the roof, do not over torque the bolts when putting it back on. The roof of the RV is curved, the bottom of the AC unit is not. If you over torque the hold down bolts, the housing will distort and the top cover will not fit properly. I had to loosen the bolts a little to make everything fit right. I ended up torquing them just enough to compress the foam about half the distance between when the foam touches the roof and the bottom plastic pan of the AC unit. Hope that makes sense.

One has to wonder why it is so hard to align these things at the plant.