INSTRUCTION TO SERVICE
ITS: 6178
SECTION:

405-05 Artic Joint

WRITTEN BY:

Dwayne Peters

SUBJECT:

Torque Access Holes

ITS6178

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 UNAUTHOIZED 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.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Raise coach in accordance with the New Flyer Service Manual. A pit can also be used.
3. Remove the four screws securing the center plate on the top of the top center cross beam. Figure 1.

Figure 1: Top plate on the top of center cross beam
4. From under the bus open the bellows to expose the bottom strut bolts. Remove the four bolts holding the
aluminum bottom strut. Figure 2.

Figure 2: Remove the bottom strut

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5. From under the bus support the bellow frame on each side with bottle jacks. Jack just enough to support the
weight of the top center cross beam and bellow frame. DO NOT FORCE. Figure 3.

Figure 3: Lightly jack the bellow frame
6. From the top, remove the four nuts/bolts securing the top center cross beam to the joint assembly. Figure 4.

Figure 4: Top center cross beam nuts/bolts
7. From under the bus, jack the sides of the bellow frame so the top center cross beam is high enough to place a
steel plate between the top center cross beam and yoke plate. (About 1”)

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8. Place a steel plate on top of the yoke plate in the drilling path to protect the top of the yoke plate and plastic
sliders and to catch the drilling debris.
NOTE:

When drilling through the drip tray, the drill bit will hit the steel plate. Stop drilling once the
drill bit passes though the drip tray so to prevent damage to the top of the yoke plate and
plastic sliders.

9. Use a drill guide with an OD the same size as the existing holes in the top center cross beam and place it in
the hole and drill a pilot hole into the drip tray. Figure 5.

Top center cross beam

Drill through the drip
tray using the existing
holes in the top center
cross beam as a
template, 4 places

Drip tray

Figure 5: Top center cross beam and drip tray
10. Continue drilling the drip tray while increasing the size of the drill bit until the max drill size of .75”
11. Repeat steps 9 and 10 for the remaining 3 holes.
12. Remove all sharp burrs from bottom of the drip tray from the four drilled holes.
13. Clean all drilling debris.
14. Lower the jacks and align the four holes in the top cross beam with the four holes in the joint assembly.
15. Install the four bolts and four lock nuts finger tight.
16. From under the bus remove the bottle jacks and reinstall the bottom strut and bolts and torque to 7 FT-LB.
17. Close the bellow openings.
18. Torque the four lock nuts to 22 FT-LB.
19. Reinstall the top cover plate ensuring the seal is in place and tighten the four screws.
20. If necessary, lower coach in accordance with the New Flyer Service Manual.
21. Turn the main battery disconnect switch to the “ON” position

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. LABOUR

ESTIMATE
Operation

1

Drill access holes in the ATG drip tray

Men

Hours

1

1.0

Labour Time
M X HR
1.0

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