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Peterbilt Standard (Pre-Unibilt) Flat Panel 1006 4/25/17

Pre-Inspect Truck

(You need to know what works before starting to disassemble.) Marker Horn

Speakers Heater

Washer Pump ABS Brake System Rear Utility Lights

Evacuate A/C & Drain Heater Lines to Sleeper.

Disconnect Battery.

Block Floor on Cab behind Door & In Front of Air Ride.

Loosen Air Ride Bolts and Prep for Removal

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Fasteners used in installation depends on what hardware kit you ordered.

B8-6 – Panel Installation (Huck and Rivet)

B8-6 – Panel Installation (Huck Only)

Interior Screw – Interior Installation

Sleeper Removal:

Remove seats from cab. You will not be able to install interior panel with seats installed. Disconnect sleeper wiring running from cab to sleeper. Check behind cabinet in sleeper and behind corner interior of cab to find wire disconnect. Remove bolts connecting sleeper to cab.

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Prep Cab:

Method 1 for removing hucks: Drill the hucks by center punching huck heads first. Then, start drilling free-hand. Once hole is established use clamp to apply pressure. Method 2 for removing hucks: Pull out interior to expose the huck collars and cut the collars off at the shoulder. Cut collars off here. Caution: We do not recommend grinding rivets. This kit will not cover your grind marks. Plug kits will only overlap rivets 1/8”, so use some caution if you chose grinding. Drill top roof cap rivets as your kit will go underneath of roof. If your truck was built after 4/06/91, there will be 4 holes on each side in the center that will not match our pattern. Simply drill these holes through our panel and continue with installation. On the bottom of the cab there is an overlap from the factory, you can just go over it or you can trim the overlap so it will not wrinkle your panel. Make sure that the surface is smooth and that there are no burrs or shavings left on cab, as this will dent the aluminum when riveting back on truck. 1

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Pre Fit Plug Kit:

Place panel on cab. The top of panel will go underneath existing roof. Use as many alignment punches as needed to align holes. All kits are predrilled for a huck hardware kit. If a rivet kit was ordered, you will need to drill all holes (panel and cab) with a 17/64” drill bit once panel is aligned. Remove panel and remove shavings and deburr holes. Apply sealer and install panel fully. 2

Sealer: When sealing panel, use a small amount of Alumilastic (included) on panel or cab. Spread thin using a small putty knife. You only need a thin layer to achieve a good seal. Do not leave a bead of sealer and then try to rivet. You will end up denting the panel. To assure a proper seal you may wish to use the remaining sealer on the inside of your cab (a silicone sealer will also work for sealing the inside).

Riveting Caution: Rivets must fit loose. Rivets must be inserted straight.

Paint Caution: Aluminum Panels are primed with aluminum conditioning primer that contains an acid base. This coating should not be removed. Lightly scuff and apply your preferred epoxy primer and paint.

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GASKET-WINDOW INSTALLATION:

You will need a window gasket tool. You can purchase one through your local auto store.

Outside of truck (gelcoat/painted side)

Glass Side Panel Side

W1

Clean area of debris around window opening.

Start installing the gasket by placing one end in the lower center of the window cutout.

Work your way around the opening.

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W2

Window Gasket Installed

Make sure that the two ends meet up and touch flush.

W3

Remove bump-pads from glass (if attached).

The side with the Daycab Company sticker goes towards the outside of the truck (painted side of

panel).

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W4

Start glass installation by sliding in a corner into gasket (+) and pivoting other side into opposing

corner.

Use gasket tool to “flip” gasket lip over glass. You will need to use soapy water/window cleaner to get gasket lubricated. This will make glass installation a lot easier. Once you get glass fully inserted into gasket, you will need to use the gasket tool to push the locking flap into the gasket around the whole window. This locks the window into place.

Make sure that the gasket ends are forming a tight seam

W5

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Inspect the corners to make sure that no wrinkles are visible and that the locking flap is tight.

W6

Interior:

Install interior panel after gasket window is installed. Center panel on window gasket, height-wise and width-wise. Interior panel is predrilled. Use Black 1” interior screws to install panel.

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If you are changing the “USE” of your truck/tractor (i.e. changing from 5th wheel to dump bed), you should contact a local brakes or parts dealer for information on changing the brake-proportioning valve. You may end up with only front brakes.

Sometimes when converting from a sleeper to a day cab you will evacuate the AC lines and cut the lines leading to the sleeper. Use your own judgement or a

certified AC technician to cap/plug the AC lines. At Daycab Company we crimp the ends and solder close.

www.daycabs.com tech@daycabs.com