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Old 09-08-2015, 11:03 PM   #1
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Head light falling out '04 Journey

On our way up to Fairbanks, a spruce grouse flew into the front of our coach. We were doing 55 mph, so it made a pretty good "clunk" and when I stopped to check it out, the driver's side headlight assembly was flopping around. The metal bracket closest to the center of the coach had come unglued from the fiberglass front cap. All the lights still function, and I did a temporary duct tape fix.

Has anyone else had to reattach that metal bracket? What kind of adhesive? Has anyone just bolted it through the fiberglass with small stainless steel bolts? Any other solutions or suggestions would be appreciated.
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Old 09-08-2015, 11:12 PM   #2
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On my previous coach, an 02 Itasca Suncruiser, I did exactly that. I used stainless machine screws with nylon washers through the front and nylocks from behind. I did the headlights and hood hinges.

I had been getting a knocking noise from time to time from the front end, ends up the brackets had pulled loose.

Everyone who looked at mine closely said they were going to do that to theirs too. Seems to be a pretty common problem.
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Old 09-08-2015, 11:17 PM   #3
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On our rig all they did was use a clear sealant to glue the headlights into the front "bumper". When we drove at night the old headlight was off spotting owls in the trees. Found the adjustment was broken and bought a new unit off Amazon. Got it installed last week. Will probably have to redo it anyway as I didn't have the right caulking gun to use the urethane I bought.
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Old 09-09-2015, 03:59 PM   #4
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I have the O4 Journey. The mastic they use to glue on hardware to the fiberglass can come undone. I have had the generator door come off one side, a wheel well fairing, and the rear area had a spot. I used pop rivets to repair them. Do it evenly and balanced they don't look too bad.
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Old 09-09-2015, 04:00 PM   #5
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There have been other posts about this problem. Do a search
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2004 Winnebago Journey 39K on a Workhorse chassis w/ ISC 330, Allison 3000
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Old 09-09-2015, 11:08 PM   #6
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I tried several searches, but they only work if you know the magic words.
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New to us '04 Journey 36 with 330 Cat will be towing a '14 Sonic 1.4 liter turbo 6 spd. '05 Dodge 3500 Cummins, '09 Subaru Outback, plus a few other toys that help us get around in Alaska.
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Old 09-10-2015, 08:45 AM   #7
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I used gorilla glue on mine 2 years ago and still holding strong. Ruff up the surface clean spray water on both surfaces and put the parts together. Clamp them if you can. For any body areas leave the old glue on just ruff it up because the old bonding is like a shim now.


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