NHTSA ID Number: 10044260
Manufacturer Communication Number: ITS: 4924
TSB/Document Date: 2012-05-30
Summary
NEW FLYER
: CERTAIN LOW FLOOR MODELS-40FT, DSL, ELEC, HAVE REAR SUSPENSION RADIUS RODS THAT NEEDS TO BE REMOVED AND REPLACED. NO MODEL YEARS LISTED. *PE
SB-10044260-9399
Page 1 of 8
THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER
OF AMERICA INC. AND ARE DISCLOSED BY NEW FLYER IN CONFIDENCE. THIS DOCUMENT
AND THE CONTENTS HEREIN ARE NOT TO BE DISCLOSED BY THE INTENDED RECIPIENT
WITHOUT THE PRIOR WRITTEN AUTHORIZATION OF NEW FLYER. ANY UNAUTHORIZED
DISCLOSURE, REPRODUCTION OR OTHER DISTRIBUTION OF THIS DOCUMENT OR
INFORMATION IS STRICTLY PROHIBITED AND MAY RESULT IN ACTION BEING TAKEN
AGAINST THE PARTY MAKING THE UNAUTHORIZED DISCLOSURE. THIS DOCUMENT AND
ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.
INSTRUCTION TO SERVICE
SECTION:
204 Rear
Suspension
MODEL:
TYPE:
30FT
35FT
40FT
60FT
HIGH FLOOR
DSL
LNG
ELEC
LOW FLOOR
ITS:
4924
WRITTEN BY:
G. Mankoo
OBJECTIVE/SUBJECT:
Remove & Replace Rear Suspension Radius Rods
PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Raise coach in accordance with the New Flyer Service Manual.
3. Locate the lower and upper radius rods on the rear suspension as shown in Figure 1.
Page 2 of 8
ITS:
LOWER RADIUS
ROD
LOWER RADIUS
ROD
UPPER RADIUS
ROD
UPPER RADIUS
ROD
FIGURE 1: UPPER & LOWER RADIUS RODS
4924
Page 3 of 8
ITS:
4924
4. Start with the upper radius rods:
a. Disconnect the left upper radius rod on both the axle and frame ends.
Discard all
associated hardware.
b. Install new windowed upper radius rod (PN 466468) on both the axle side and frame side
following Figure 2.
NOTE: Apply never seize (PN 5928660) on all mounting hardware threads and torque
to specific values using low speed installation (NO IMPACT TOOLS).
c.
Repeat Steps 4a & 4b for the right upper radius rod.
Page 4 of 8
ITS:
BOLT PN 356808 (2 PLCS)
SPACER PN 223196 (2 PLCS)
NEVER SEIZE PN 5928660 (2 PLCS)
4924
WASHER PN 20W12000 (2 PLCS)
TORQUE TO 300 FT-LBS
(NO IMPACT TOOLS)
UPPER RADIUS ROD
PN 466468
(LEFT & RIGHT SIDE)
BOLT PN 10B12064 (2 PLCS)
SPACER PN 223196 (2 PLCS)
NEVER SEIZE PN 5928660 (2 PLCS)
TORQUE TO 300 FT-LBS
(NO IMPACT TOOLS)
WASHER PN 20W12000 (2 PLCS)
(LEFT & RIGHT SIDE)
FIGURE 2: UPPER RADIUS ROD ENDS
Page 5 of 8
ITS:
4924
5. For the lower radius rods:
a. Disconnect the left lower radius rod on both the suspension and frame ends. Use special
tool PN 6407374 to hold the bolt head of the radius rod mounting bolts, while removing
the retaining nuts. Discard all associated hardware.
NOTE: Use of special tool PN 6407374 allows for removal and installation of the lower
radius rod mounting bolts on the suspension end without removing the rear
tires.
b. Install new windowed lower radius rod (PN 466467) on both the suspension side and
frame side following Figure 3. Use special tool PN 6407374 to hold the bolt head of the
radius rod mounting bolts, while tightening the retaining nuts.
NOTE: Apply never seize (PN 5928660) on all mounting hardware threads and torque
to specific values using low speed installation (NO IMPACT TOOLS).
c.
Repeat Steps 5a & 5b for the right lower radius rod.
Page 6 of 8
ITS:
LOCKNUT PN 130733 (2 PLCS)
WASHER PN 20W12000 (2 PLCS)
NEVER SEIZE PN 5928660 (2 PLCS)
4924
BOLT PN 10B12104 (2 PLCS)
WASHER PN 20W12000 (2 PLCS)
TORQUE TO 193 FT-LBS
(NO IMPACT TOOLS)
USE SPECIAL
TOOL PN
6407374 TO
HOLD BOLT
HEAD WHILE
REMOVING OR
TIGHTENING
RETAINING
NUTS
LOWER RADIUS ROD
PN 466467
WASHER PN 20W12000
(2 PLCS)
SUSPENSION SIDE END
(2 PLACES)
WASHER PN 20W12000
(2 PLCS)
BOLT PN 10B12064 (2 PLCS)
SPACER PN 223196 (2 PLCS)
NEVER SEIZE PN 5928660 (2 PLCS)
TORQUE TO 300 FT-LBS
(NO IMPACT TOOLS)
FRAME SIDE END
(2 PLACES)
FIGURE 3: LOWER RADIUS ROD ENDS
Page 7 of 8
ITS:
6. Lower coach in accordance with the New Flyer Service Manual.
7. Turn the main battery disconnect switch to the “ON” position.
4924
Page 8 of 8
ITS:
4924
LABOUR ESTIMATE
Operation
1
Remove & Replace Rear Suspension Radius Rods
Men
Hours
1
4.0
Labour Time
M X HR
4.0
PARTS REQUIRED
Item
Part Number
1
466468
Description
ROD-UPPER REAR RADIUS
Qty.
per
Coach
2
Units
2
EA
0.01
EA
Notes
EA
WINDOWED
2
466467
ROD-LOWER REAR RADIUS
WINDOWED
3
5928660
NEVER SEIZE
4
223196
SPACER-RADIUS ROD MTG
12
EA
5
356808
BOLT-M18 X 1.5 X 100 CL10.9
4
EA
6
20W12000
WASHER FLAT HARDENED 3/4"
24
EA
7
130733
NUT-LOCK UNITORQUE 3/4
4
EA
8
10B12104
BOLT-HEX 3/4 UNC X 6.50
4
EA
9
10B12064
BOLT HEX 3/4" 10 UNC X 4" LG
8
EA
SPECIAL TOOLS REQUIRED
Item
Part Number
1
6407374
Description
TOOL-DRIVE 1/2 FLEX BAR
MODIFIED
Qty.
per
Coach
1
Unit
of
Measure
EA
Notes
1 Tool Per
Property
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TSB/Document ID: ITS: 4924
Replacement Service Bulletin Number:
MFR Communication Date: 2012-05-30
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SUSPENSION:REAR
MFR Component System:
MFR Component Subsystem:
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