Thread: The Next in Line Project

One of the main reasons I pulled the Camper in was to replace the failed Cooling Unit in the refrigerator. I could buy a new refrigerator but I could not get the door panels to match the ones we have and this is not the first time I replace a cooling unit so I went the repair route.



Now that the camper is inside it will be getting a lot of attention. I first disconnect the refrigerator then remove the screws inside the freezer section and refrigerator fin section along with the shelves and door organizers.



You can see I have the refrigerator laying face down on the floor ready to start disassembly.



So all the stuff on the back has to be removed, the control board, burner, wiring, gas valve, etc before the cooling unit itself can be removed.



A lot of times you have to rig up to pry out the cooling unit but I was able to get this one free without too much fight. I did say it's not my first, you learn quickly doing these replacements. Going back in with the new unit a Thermal Mastic must first be applied to the coil to transfer the cooling to it aluminum plates & fins still in the box. I forgot to take pictures, was totally focused on the task but there is plenty of videos online that show this entire process.



The tubing exposed but embedded in the foam block is where the mastic is applied. You apply the entire tube, every bit.



All the old tape, foam bits, or anything else that may prevent the coil for full contact with the plates must be removed. Then if you look at the first picture that is the freezer plate and the screw holes are bent in. You use a hammer, I also used a transfer punch, using the center to prevent missing the strike point center but using the flat face to catch the place flattening out the crowns. In the second picture I used a sharp drill bit to slightly enlarge the screw holes to ease starting the screws into the new cooling unit mounting holes.



After placing the new cooling unit in you add a couple of mounting screws to the frame to keep it in place then stand up the refrigerator opening the doors and screw the cooling unit to the freezer plate and refrigerator fins. Here I'm adding a fan assembly to the fins to prevent them from freezing up, a common problem with Dometic refrigerators as well as improving the temperature uniformity all over inside the box.




Once you have the interior screws installed you lay the refrigerator back on it's face and using a GE Windows & Doors expanding foam fill the voids between the refrigerator body and the cooling unit.



After allowing the foam to fully cure I very, very, carefully trimmed the excess foam away as I didn't like that the foam cut off the air flow on the first back coil turn and the tip of the foam can didn't penetrate about a 4in section due to contact from the cooling unit foam block. The Amish manufacturer of the cooling unit said a 2 inch air leak in the back here could prevent the unit from working properly. I can't see it but I'm certified with Freon refrigerants not ammonia refrigerants. They sent me a small roll of aluminum tape to apply over the foam but wrote very specifically their tape was "cosmetic only". Well I don't do things like that so Monday I have to run over to Johnstone Supply and pick up some Aluminum Mastic Tape. Once applied its like trying to remove Gorilla Tape but made for sealing this exact application. Once I apply that I have a double seal.