Storage space roof sector

Overhead storage compartments in the cab make use of the space above the windscreen, doors, beds or side windows, keeping documents, personal protective equipment, small tools and onboard equipment safely within easy reach. In long-haul cabs of the MAN TGS, TGX and TG3, as well as Mercedes Actros, Arocs and Atego cabs, these roof storage compartments are an important part of ergonomics and living comfort. Overhead compartments are also found in MAN Lion’s City, Lion’s Coach, Neoplan coaches and Mercedes Citaro or Tourismo buses, often with a different layout and mounting method. The correct compartment, flap, hinge or mounting bracket must always be identified using the vehicle chassis number. Visual comparison or selection based solely on the model name is never sufficient.

Overhead storage compartments vary significantly according to cab series, roof height, sleeper cab version, interior colour, installation position and fitted equipment such as interior lighting, speakers, tachograph modules or HVAC ducts (Heating, Ventilation and Air Conditioning). For example, a MAN TGX XXL has a different compartment height, contour and mounting rail than a TGX XLX or a TGS LX. For Mercedes Actros, parts vary between Lang GigaSpace, Lang BigSpace, Lang StreamSpace and Lang ClassicSpace, among others. A Sprinter, Vito or TGE may also have an overhead document compartment or roof console, but the load-bearing structure and screw positions are not interchangeable with those used in trucks or buses.

Most compartments are made of impact-resistant thermoplastic, often ABS (acrylonitrile butadiene styrene) or PP (polypropylene), with reinforcing ribs on the rear. They are mounted using metal brackets, plastic clips, guide pins and self-tapping screws in a reinforced cab roof profile. Correct fitment of the locating pins, undamaged threaded mounting points and even contact with the headlining are crucial. A compartment installed under tension may crack around the mounting points, come loose or cause rattling noises due to cab flexing or vibration.

Common faults include broken hinge lugs, worn flap hinges, cracked mounting tabs, missing dampers and defective latches. Overloading is a major cause: full bottles or loose metal objects create high dynamic loads during braking manoeuvres and on poor road surfaces. In vehicles with worn cab silent blocks or cab shock absorbers, these vibration peaks increase, causing fatigue cracks especially at the rear mounting points and in thin-walled plastic areas.

First open and close each flap several times and check whether the latch engages fully without having to manually press on the compartment. Measure flap play at both hinge points; uneven play generally indicates a distorted hinge housing or a worn pin. Then use an inspection lamp to check the rear panel, ribs and mounting lugs for hairline cracks. Do not pull hard on the compartment: assess the mounting by applying light pressure in longitudinal and transverse directions. Movement between the compartment and the roof structure indicates loose clips, torn-out screw holes or a damaged support bracket. On compartments with integrated lighting, also inspect the plug connections, cable grommets and earth connection for corrosion or pinched wiring.

Replace an overhead compartment completely when load-bearing ribs, hinge housings or several mounting points are cracked. Plastic adhesives or welding may provide a cosmetic repair, but are generally not a durable solution in load-bearing mounting areas. Preferably also replace worn latch pins, clips, dampers and damaged screws; a new compartment fitted to old, loose mountings will not have the correct service life. Before installation, clean the contact surfaces and remove any remaining plastic fragments from the headlining or mounting profiles.

First fit the compartment hand-tight at all locating points, then tighten the mountings diagonally according to the specified tightening torques. Excessive tightening can compress plastic bushes or crack screw lugs. After installation, check the free movement of flaps, lighting and any sun visors. Correct fitment reduces resonance noise and prevents loose cab components from distracting the driver. Availability of suitable cab parts and technical support with identification help minimise downtime for professional vehicles.