SB-10054616-8711

New Jersey Transit: Steering Gear
Mounting Plate Weld
Prepared by: David McCombs, ME
Kalman Takacs, Field Service Engineer
Approved by: Dan Allen
Chief Engineer
Property name and Top bus number: New Jersey Transit - 164200

Issue: Welds on Steering Gear Mounting Plate
Reason/ cause:

New Jersey Transit identified manufacturing variability of the welding of the
steering gear plate. This work instruction implements an engineering
deviation to correct the non-conformance.

Solution:
Group 1: Need to add 12” weld inside of the mounting plate.
Group 2: buses have more than 12” but less than 40” exterior welds on the mounting
plate: Need to add 12” weld inside of the mounting plate.
Group 3: buses have less than 12” weld on the exterior: need to remove steering gear
and weld continuously on the exterior and add 12” inside of the mounting plate.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

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New Jersey Transit: Steering Gear
Mounting Plate Weld
Number of affected buses:
Group 1 buses: need to add 12” weld inside of the mounting plate: 5202-5211, 5213, 52155218, 5221-5225, 5227-5228, 5231-5236, 5237, 5239, 5240
Group 2 buses where need to add weld inside of the mounting plate:
5201, 5212, 5219, 5229, 5238, 5241-5251, 5254-5259, 5261-5264, 5266-5269, 5271-5272,
5274, 5276-5284, 5286, 5288-5295, 5297, 5299, 5301-5304, 5307, 5311, 5313, 5323, 5336,
5366-5369, 5371, 5374, 5376, 5378-5385, 5387-5389, 5391-5396, 5399, 5400, 5402-5305,
5428, 5430-5435, 5437-5438, 5442, 5445-5448, 5450, 5501-5502
Group 3 buses where need to weld continuously outside and add weld inside of the
mounting plate:
5214, 5220, 5252, 5260, 5265, 5270, 5273, 5275, 5285, 5287, 5296, 5298, 5300, 5305-5306,
5308-5310, 5312, 5314-5322, 5324-5335, 5337-5345, 5347-5365, 5370, 5372, 5375, 5377,
5386, 5390, 5397-5398, 5401, 5436
Estimated hours/bus: 5.0 Manhours
Engineering Documentation: Engineering Deviation N09-15076 – Underbody Front,
Engineering Drawing 10A-6141-000 – Underbody, Front – reference part number 10A-6141-165
- Gearbox Bracket, Weld Specifications: 10A-6000-911 – Welding and Build-Up Instructions,
10A-6000-914 – General Welding Machine Settings, 10A-6000-915 – General Weld Repair
Instructions
Necessary parts:
Weld Wire: Size - .035, Type – Carbon to Stainless Steel, Specification –
SFA/AWS A5.9 ER309LSi,
NABI P/N: 660309A
Primer:
Cardinal P/N: A-4108-E10128-Gloss Gray
Undercoating, Sound Dampng, 7779 GY:
NABI P/N:
700-2603-001-03
Bolt, M20x1.5x35, hex head, 10.9:
NABI P/N: 01503-62035,
as required,
Washer, 20K-2, Lock,
NABI P/N: 05020-60020,
as required
Necessary tools:
Die grinder with wire wheel/deburring bits, air file, MIG welding machine, welding blanket, jacks,
jack stands, ladder, various hand tools, torque wrench capable to 450 lb-ft.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

2/8

New Jersey Transit: Steering Gear
Mounting Plate Weld
SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY
STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.
Keep all sparks, flames, and other sources of ignition away from flammable materials.
Have a fire extinguisher within hand reach.
1.
2.

Deploy wheel chair lift before disconnecting power.
Position main battery switch in OFF position. Disconnect negative battery cable.

3.

Disconnect the following:
a) Front Destination Sign – 3 connectors inside front destination sign compartment.

b) TCM – 1 connector inside street side light compartment at rear of bus.
NOTE: Use extra care removing and reinstalling connector to prevent damage to pins.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

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New Jersey Transit: Steering Gear
Mounting Plate Weld
c) Electrical Harnesses – 3 connectors inside wheel chair lift compartment – behind
entrance door.

d) Harnesses – 3 connectors inside engine compartment - curb side above coolant fill.

4.

On the inside of the bus, remove driver’s seat and plate underneath driver’s seat for
access to the top side of the steering gearbox mounting plate.

Seat mounting
bolts

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

4/8

New Jersey Transit: Steering Gear
Mounting Plate Weld
On Group 3 buses:
5.

Use jacks to lift bus high enough to work under. Position jack stands at jack pads
underneath the bus. Lower bus onto jack stands. Remove wheel chair lift cover panels
for access to steering gearbox mounting plate.

6.

If necessary, remove clamping hardware on air harness and water lines underneath the
bus next to the steering gear mounting plate. Move harness and lines over for access to
plate. Cover harness and lines with welding blanket to protect from welding sparks and
debris.

7.

Remove steering gear mounting bolts and lower the steering gear. Do not disconnect
hydraulic hoses and draglink.

8.

Use die grinder with wire wheel and deburring bits and air file to remove all undercoating
and primer from area to be welded. Use same tools to clean and prep top side of plate
for area to be welded. Base metal must be exposed at all weld areas.

9.

Weld bottom side of steering gear mounting plate by connecting the existing stitch welds
together using a ¼” fillet to make a solid weld bead all around the plate.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

5/8

New Jersey Transit: Steering Gear
Mounting Plate Weld

Welds

On Group 1, 2 and 3 buses:
10.

Weld top side of steering gear mounting plate as follows:
a) S/S Front Corner - Apply ¼” fillet welds x 1” long on either side and around corner
leaving room for removal of bolt.
b) C/S Front Corner – Apply ¼” fillet weld from middle support tube toward curb side
stopping at a point to allow for removal of bolt.
c) S/S and C/S Rear Corners – Apply ¼” fillet welds from middle support tube around
corners. End weld at 1” past corners.
d) S/S and C/S Edges – Apply ¼” fillet welds x 1” long on 2” centers along both edges of
plate.
S/S
Welds

Front

Rear

C/S

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

6/8

New Jersey Transit: Steering Gear
Mounting Plate Weld
NOTE: On Group 2 buses – steering gear not removed: After welds have cooled and prior to
application of primer check the torque value of steering gear mounting bolts. Use torque
wrench to ensure bolts are at minimum of 405 ±3% ft-lbs.
11.

After welds have cooled, clean welds and adjacent structure around welds and apply
primer to areas where it was previously removed – top & bottom of plate.
NOTE: Approved primer is Cardinal part number A-4108-E10128-Gloss Gray.

12.

Allow primer to dry on bottom side of plate and use a paint brush to apply undercoating to
all areas where it was previously removed. Approved undercoating is NABI part number
700-2603-001-03 – Undercoat, Sound Dampng, 7779 GY.

13.

Reinstall steering gear. Apply Sikalock and torque bolts to 405 ±3% ft-lbs. Use new bolts
if original bolts damaged. Apply torque seal to the head of the bolts. (Group 3 buses
only).

14.

Connect existing clamps and hardware to secure water lines and air harness if previously
removed.

15.

Install wheel chair lift cover panels using existing hardware.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

7/8

New Jersey Transit: Steering Gear
Mounting Plate Weld
16.

Remove jack stands and lower the bus back to the ground.

17.

Install cover plate in driver’s floor using existing hardware.

18.

Install driver’s seat using existing hardware. Tighten the four 3/8-16 bolts to 40 ft-lbs.

19.

Reconnect all electrical connectors previously disconnected.

20.

Reconnect negative battery cable and position battery switch to ON position.

21.

Retract and stow wheel chair lift.

22.

Check for completion of all steps.

Work instruction number: L3/FSV-213
L4/QUA-003

Revision: A

Date: 12/13/2013

Revision: Initial

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