L3-FSV-195 Service Bulletin/Repair Instructions

GCRTA: Chassis Rework
Prepared by:
Kalman Takacs

Sr. Field Service Engineer
Approved by:
Dan Allen

Chief Engineer
Property name and Top bus number:
GCRTA 76000, 87000, 125000, 128000
Issue:
Structural issues were reported by the customer.
Reason:
Structural upgrades to enhance durability.
Solution:
Reinforcing the effected area per this work instruction.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
1
GCRTA: Chassis Rework
Effected buses: 70 buses chosen by GCRTA will be inspected and welded as required. The

inspection and crack repair is detailed in this work instruction. 248 buses will be reinforced per this

work instruction

Estimate repair hours/bus: 1-3 hours on the 70 buses, 10 hours on the 248 buses

Necessary parts:

U-channel, outer for 3rd crossmember,

Part #: V01-6103-011A,

rd

Part #: V01-6103-111A,

U-channel, inner for 3 crossmember,

rd

Two angle pieces for the center of 3 cm,

Part #: V02-6103-001,

rd

L-profile, Mud flap holder, 3 cm,

Part #: 511-6144-063,

Gusset, upper part, left (street side),

Part #: 529-6143-003,

Gusset, upper part, right (curb side),

Part #: 529-6143-003T,

Gusset, lower part, left (street side),

Part #: 529-6143-004,

Gusset, lower part, right (curb side),

Part #: 529-6143-004T,

Welding wire, ER 309LSi, dia. 0.035”

Part #: NPN,

Industrial primer,

Part #: NPN,

Sikaflex 221, White, sealer,

Part #: 416.00.7311.909,

Rubberized undercoating:

Part #: NPN,

Penetrate test kit (cleaner-, penetrate- and developer sprays): NPN

See some pictures below about the possible usable products.
1/bus,

1/bus,

1/bus,

1/bus,

1/bus,

1/bus,

1/bus,

1/bus,

as required,

1 can / 10 buses,

1 tube/5 buses,

1 can / 10 buses,

as required
Example
Example

Necessary tools:

Usual hand tools (wrenches, screwdrivers, hammer, chisel, etc.) putty knife, Sika applicator gun,

angle grinder, GTAW Welding machine, 1/8” and 18 mm diameter drill bits, drill, wire wheel, 40G

abrasive disc, de-burr bits

Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
2
GCRTA: Chassis Rework
SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY

STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.

Stop welding 45 minutes before planning to leave the bus.
1. General Information:










Read and understand this work instruction before start repairing buses.

Study the repaired environment before start repairing.

Ensure that all tools, protective equipment and parts are available.

Departing from this work instruction without preliminary discussion is not allowed.

Number of repaired buses, mileage and date of repairing must be recorded and reported

weekly to Kalman Takacs.
2. General Preparation










Turn off the main electric switch.

Tag and disconnect the battery cables.

Disconnect the ECU of engine, transmission, ABS. Disconnect the destination signs. Turn

off and disconnect the PA system.

Lift the bus and place jack stands underneath the official jack pads.

Protect repaired area from damage, grinding spark and welding splatter.
Cover the hydraulic lifts

with fire proof blankets



Remove coating material and primer from welded surfaces by using grinding tools and wire

wheels. Primary condition of good quality weld is a perfectly clean metal surface.

Remove dust and degrease cleaned areas with acetone.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
3
GCRTA: Chassis Rework
3. General Welding instruction:

3.1 Weld just a clean surface! Grind surfaces with grinding disk suitable for stainless steel material.

3.2 To prevent gas defects of the weld joints welding should be performed only in closed

production area protected from currents of air.

3.3 Welding parameters according to attached WPS sheets.

3.4 Weld joints should be 100% visually inspected (VT), penetration (PT) if necessary.

3.5 Protect repaired area from damage during welding.

Make sure that no cracks are present at the area where reinforcement parts will be installed. If

crack was found, then follow the steps below:
















Find the end of the crack (it is recommended to use magnifier, or PT),

Drill a 1/8” size hole at the end of the crack,

Bevel the crack profile 2x30° for single “V” butt (groove) weld,

Clean the surface at the welding area (mechanical cleaning).

Degrease surface at the welding area by using acetone or denatured alcohol.

Weld the cracked and bevelled line with continuous weld per WPS CL-R51.

Grind the weld surface until the same height as the parent metal.

Check the welds by Visual Test and/or Penetrate Test.
Note: inspect for crack(s) at the following areas on every bus:


Front radius rod brackets area (left and right sides).
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
4
GCRTA: Chassis Rework
 Front and rear shock absorber upper brackets area (left and right sides).

 Entire 3rd crossmember: need to check both the forward and backward surfaces of

the crossmember

Exit door lower corners.
 Rear radius rod brackets area (left and right sides). See bottom left picture on the

page 11.

Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
5
GCRTA: Chassis Rework
4. Install Reinforcement Parts

4.1. 3rd crossmember rework

1. Remove mud flap on the center and street (left) side of the 3rd crossmember.
2. Remove QR valve from the front of the crossmember (see picture on the next page).

3. Cut the hose support bracket off. Do not damage this bracket because it has to be welded

back later.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
6
GCRTA: Chassis Rework
4. Cut the closeout plate off from the left (street side) end of the lower tube of the rossmember.
5. Cut the mud flap brackets (angle pieces) off from the crossmember. Do not cut the structure!
6. Cut the QR valve bracket off from the crossmember. Do not damage this bracket because it

has to be welded back later.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
7
GCRTA: Chassis Rework
7. Cut the static strap bracket off from the crossmember. Do not damage this bracket because

it has to be welded back later.
8. Inspect crossmember and if crack(s) were found then prepare them according to the

General Welding Instruction section. Do not weld crack(s) at this time, just prepare (drill the

ends, bevel, etc.). Weld cracks only after the inner U-channel and extension pieces have

been installed. See step 15.

9. Drill 12 ea. 18 mm diameter holes as pictures show below.
50 50 170
50
All dimensions are mm
10. Grind / sand the surfaces around the welding area smooth.

11. Check that the new reinforcement parts fit the structure: check position, gaps, etc. and

modify as required.

12. Cover nearby hoses and harnesses with fireproof blankets or aluminum foil. Ensure that

fire extinguishers are handy before start welding.

Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
8
GCRTA: Chassis Rework
13. Plug weld the inner U-channel (PN V01-6103-111A) to the crossmember according to the

WPS CL-R52.

WPS CL-R52
Extension piece, PN V01-6103-011A
WPS CL-R01
WPS CL-R05

Do not weld here!
V01-6103-011A

14. Place the extension piece and stitch weld the upper edges of the U-channel to the 3rd

crossmember according to the WPS CL-R01, continuous weld the joints of the extension

piece and the lower tube of the crossmember according to WPS CL-R05 and plug weld to

the inner U-channel according to the WPS CL-R52.

15. Weld crack(s) (if any) as described at the General Welding Instruction section.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
9
GCRTA: Chassis Rework
16. Install outer angle pieces (PN V02-6103-001) and stitch weld their upper edges to the 3rd

crossmember and plug weld at the holes according to the WPS CL-R52.
a3

WPS CL-R52
17. Reinstall mud flap holder L-profiles (PN 511-6144-063) with 3x1” long stitch welds per WPS

CL-R01.

18. Reinstall QR valve bracket.

19. Reinstall static strap bracket.

20. Remove weld splatters and clean welded surfaces.

21. Check the welds by Visual Test and/or Penetrate Test.

22. Apply industrial primer. Let the primer dry. Follow instructions written on the can.
23. Apply Sikaflex 221 sealer around the stitch welded edges of the reinforcement parts.

Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
10
GCRTA: Chassis Rework
24. Apply rubberized undercoating. Follow instructions written on the can.
25. Reinstall removed parts (QR valve, mud flap, static strap).
4.2. Rear Radius Rod Bracket Area Repair

1. Locate rear radius rod brackets (left and right sides).

Left (street side) rear

radius rod bracket area
Crack
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
11
GCRTA: Chassis Rework
2. Remove clamp and pull harness/air hoses away from the work area (see below).
3. Protect nearby hoses and harnesses against sparks by using fireproof blankets or aluminum

foil.

4. Clean top of the fuel tanks and cover them as well with fireproof blankets. The dirt soaked

with fuel is very flammable. Ensure that fire extinguishers are handy before start

welding.

5. Inspect rear radius rod bracket area for crack(s). Repair cracks according to the General

Welding Instruction section.
6. Remove undercoating from the structure where the gussets will be welded on.

Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
12
GCRTA: Chassis Rework
7. Place the upper part of the gusset (PN 529-6143-003 for left side and 529-6143-003T for the

right side) to the structure and check for proper gaps, position of gusset.

8. Weld upper part of the gusset per WPS CL-R02.

PN 529-6143-003
a3

WPS CL-R02
9. Place lower part of the gusset (PN 529-6143-004 for left side and 529-6143-004T for the

right side) to the structure and check for proper gaps, position of gusset.

10. Weld lower part of the gusset per WPS CL-R02.

Right (curb side)

gusset is installed
Left (street side)

gusset is installed
a3

WPS CL-R02
a3

WPS CL-R02

PN 529-6143-004T
PN 529-6143-004
11. Remove weld splatters and clean welded surfaces.

12. Check the welds by Visual Test and/or Penetrate Test.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
13
GCRTA: Chassis Rework
13. Apply industrial primer. Let it dry. Follow instructions written on the can.
14. Apply Sikaflex 221 sealer at the top edges of the upper gusset pieces.
Note: the Sikaflex 221 sealer

must apply after the bracket is

primed
15. Apply rubberized undercoating. Follow instructions written on the can.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
14
GCRTA: Chassis Rework
16. Move harnesses/air hoses back to their original position and secure them with the original Pclamp. Ensure that the harnesses/hoses are not rubbing on moving components (C-frame,

air bags, shock absorber and wheels).
17. Remove all tools, unused parts and blankets/aluminum foils from work area.
5. FINAL OPERATIONS

1. Present final repairing for check to delegated person.

2. Remove jack stands from underneath the bus.

3. Lower the bus, document the repairing.

4. Reconnect the ECU of engine, transmission, ABS. Reconnect the destination signs.

Reconnect the PA system.

5. Reconnect the battery cables and turn on the main electric switches.

6. Start the bus (GCRTA technician) and function test all electrical components.
Work instruction number: L3/FSV-195

L4/QUA-003
Revision: Initial
Date: 09/19/2013

Revision: Initial
15

SaleBestseller No. 1

Autel Scanner MaxiCOM MK808S: 2026 Bidirectional Tool as MX808S MK808BT Pro M808Z, Work as MaxiCheck MX900 MK900BT, 28+ Service, 3000+ Active Tests, All System OBD2 Diagnostics, OS 11, 10X Faster

💝【Questions? We’re Here Anytime】MK808S is a high-end flagship model that connects via wired OBD2 for faster, more stable, and reliable diagnosis compared to B,.T tools. If you have any questions about setup, activation, features, additional accessories, or update subscriptions, please reach us and we will respond promptly to assist you. It includes 1-Year F.ree Updates (124.5 bucks/year after), and most functions still work after expiration except a few online features. Please note some functions like full TPMS are not supported, reach us for model recommendations.
🔥🔥🔥【2026 NEWLY RELEASED BI-DIRECTIONAL CONTROL】As the 2026 upgraded version of MaxiChek MX808 MaxiDiag MD909 Pro MD906 Pro, our Newest MK808S auto diagnostic scanner for all cars inherits the powerful Bi-directional Control which makes it the most cost-effective scanner (without breaking the bank, same as MK900BT MS906 PRO MS906MAX). Active test is widely used on car subsystems to help you check if the car actuators are all in good condition. Such as windows, rear mirrors, sunroof, wipers...
【28+ MOST POPULAR RESET SERVICE FOR 150 MAKES】Autel versatile OBDII scanenr MK808S, full level-up of MX808, work as MX900, MK900, MK900-BT, supports 150+ car brands worldwide. Like the OBD2 code reader MaxiCOM MK808BT Pro, MK808S is equipped with 28+ hot services including 0il Reset, SAS Calibration, ABS Bleeding, Battery Registration, etc. MK808S ranks top in professional automotive tablets and keeps updating to support more newer modes from 2025 to 2026.
【ALL SYSTEM DIAGNOSTICS, FACTORY-LEVEL SCANNER】The MK808S dealer-level scanner, like Snap-on tools, effectively works all cars for all system diagnostics. It reads/clears codes, displays 5-in-1 Live Data, performs active tests, and special functions for all available modules. With a few clicks, you can easily understand the vehicle's condition. The convenient Wi-Fi printing feature allows you to generate a detailed report, highlighting the exact nature of the problem.
【AUT0 SCAN & AUT0V1N, 10X FASTER】How much have you spent on car maintenance? Even a minor issue can take up a significant amount of time. The MK808S is designed to improve your work efficiency. With its Aut0V1N technology, you can check your car's make, model, and year information with just one click. The Aut0Scan feature automatically scans all of the vehicle's modules and detects any fault codes. Check Aut0V1N compatibility by reaching us at 📞1-833-436-5880. Available Mon-Fri, 9 AM-6 PM EST.

SaleBestseller No. 2

💯【Conta.ct us for Support Directly】If you met any issues about: Received a registered device/ Language Changing/ Function not Support/ Blueto-oth connector malfunction/ Subscription Renewal, please conta.ct us via 📞autelsupply @outlook. com🛣️, we will provide perfect solution for you. ⚠️Note: Autel MK900BT comes with 1-Year Free Software Update, most features will remain active after update subscription expires. For questions regarding updates or need more useful accessories, please conta.ct us via 📞autelsupply @outlook.com🛣️. 2. If you encounter Blueto-oth adapter VCI150 malfunction, please tell us 📞autelsupply @outlook. com🛣️, we will handle it promptly.
🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW MODEL OF MK808S MK900 MX900 MK808BT MX808S】2026 newest Autel MK900BT retains all features of MK808S MX900 MX808S MK808Z MK808Z-BT MK808K-BT, while EXTRA added powerful functions (value 2000+ bucks). The Pro-level Autel MK900BT makes a big leaps: 28+➡40+, 50+➡3000+ Active Tests, 2026 NEW✅CAN FD & DOIP protocols ✅Pre&Post diagnostic report ✅WIFI Print ✅Auto VIN&Auto Scan 2.0 ✅Scan VIN/ License ✅Battery Test (Need purcha.se BT506). If found defect or us.ed, please conta-ct 📞autelsupply @outlook. com📞 get perf-ect solut.ion.
🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS906 PRO】Differ from MS906BT MS906 MP808 MK808 MX808 MK808BT only 50 tests, Autel scanner MK900BT escaner automotriz professional offers 3000+ active tests, it can send command to ECUs & monitor actuators operation, quickly locating faulty components. Bidirectional scanning takes your diagnostics to the next level with menu lists 3000+ active tests, such as windows, rear mirrors, sunroof, wipers, fuel injector, coolant fans, radiator fan, AC clutch, coolant pump and more. Note: Functions are not available for all vehicles, please send vehicle VIN to us check compatibility.
🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full level-up of OBD2 code reader MaxiCOM MK808S MK808 MK808Z MX808 MK808Z-BT with 28 service, Autel scan tool MK900BT/ MK900-BT offers 40+ maintenance service on 150+ brands 10,000 vehicles from 1996-2025-2026. Hottest Services like: Oil Reset, ABS Bleed, SAS Calibration, Injector Coding, SRS, Throttle Reset, Gearbox Reset, Battery Registration etc. Added 12+ advanced resets: rain slash light sensor reset, HVA.C/ SUS calibration etc. Welcome to send Vehicle Make>Model>Year>VIN>Functions you required to 📞autelsupply @ outlook . com📞 check compatibility.
🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE/ AUTO VIN】2026 new release Autel MaxiCOM MK900-BT scan tool embodies all system diagnostic with its 8in display for all vehicles. Like Sna.p-on tools, it can perform ✔Read/Clear Codes✔Displays 5-in-1 Live Data✔Record & Playback Data✔Retrieve Info on all available systems like ABS ECM BCM SRS TCM etc. In addition to Auto VIN technology, Autel MK900BT adds Scan License/ Auto Scan 2.0 to identify vehicle’s VIN/ license, make, year, model, no need manual input; One-click WiFi Printing of Pre&Post comparison diagnostic reports, highlight root causes of problems.

SaleBestseller No. 3

Autel Professional OBD2 Scanner AL319 Code Reader, Enhanced Check and Reset Engine Fault Code, Live Data, Freeze Frame, CAN Car Diagnostic Scan Tools for All OBDII Vehicles After 1996, 2026 Upgraded

【TURN OFF CEL】 This AL319 car scanner diagnostic tool supports Reading and Clearing DTCs, DTC Look Up, displaying Live Data, Freeze Frame & I/M Readiness, view vehicle information, etc., to figure out the root cause of the Check Engine Light (CEL) and turn it off, helping you catch any potential issues early and avoid excessive costs from unnecessary repairs.
【EXTENSIVE APPLICATION】 Autel AL319 Compatible with 7 languages (English, French, Spanish, etc.) and various post-1996 OBD II protocol vehicles (Toyota, Nissan, Honda, Ford, etc.), this OBD II scanner provides accurate and fast diagnosis for worldwide car owners.
【FOR END USER & DIYERS】 This error code reader AL319 is “plug and play” and comes with an easy interface. Even if you’re not familiar with vehicle repair, you can quickly take control of this obd2 scanner, and get the information you want.
【USER-FRIENDLY DESIGN】 This OBD2 scanner and check engine code reader features a patented One-Click I/M Readiness, TFT color display, built-in speaker, LED Indicator etc. The cable is long enough without being too long and getting in the way. No batteries are needed.
【HIGH-QUALITY SERVICES】 12 months war.ranty from the date of purchase and lifetime free update are offered by this Automobile OBDII scan tool. Welcome to contact us via Q&A, email, or hotline, and our after-sale-service team for technical support.

This product presentation was made with AAWP plugin.

Last update on 2026-05-12 / Affiliate links / Images from Amazon Product Advertising API

Buffer Email Facebook Flipboard Hacker News LinkedIn Messenger Mix Pinterest Print Reddit SMS Telegram Tumblr X VK WhatsApp Line Xing Threads Bluesky Copy Mastodon Nextdoor