NHTSA ID Number: 10117383
Manufacturer Communication Number: SB 445
TSB/Document Date: 2017-09-14
Summary
This Service Bulletin informs affected customers that customers may experience water migration into the transmission connector and harness on MY 2013 - 2017 MCI J4500 coaches, and that the transmission interface harness wire loom may wear due to stress or movement at the point of existing p-clamps or tyraps; that either condition may result in transmission codes, the PBSS (pushbutton shift selector) not shifting, or transmission failure; and that MCI
will remedy the affected coaches at no cost to customers. This Service Bulletin must be implemented in conjunction with MCI Procedure 7-135.
Service Bulletin No. 445
MODEL
TYPE
J4500
SECTION/GROUP
Field Change Program
7-Electrical
DATE
Mar. 24, 2017
SUBJECT
TRANSMISSION HARNESS ROUTING
CONDITIONS
MCI is informing owners of the J4500 model coaches listed in this bulletin that MCI Procedure
7-135 must be implemented in conjunction with FCP Service Bulletin 445.
Upon completion of the outlined retrofit steps in FCP Service Bulletin 445, customers are
instructed to contact the MCI Fleet Support Technical Center at 1-800-241-2947 to schedule an
appointment to have the specialized trained retrofit outlined in MCI Procedure 7-135 performed
on the coach.
The transmission harness and connector retrofit is NOT complete, and may be subject to water
migration into the transmission connector and harness, until both the FCP Service Bulletin 445
and MCI Procedure 7-135 have been performed.
Customer Complaint:
Motor Coach Industries ("MCI") has become aware that the J4500 series coaches listed in this bulletin may
experience water migration into the transmission connector and harness. In addition, the potential may exist
whereas the transmission interface harness wire loom may wear due to stress or movement at the point of
existing p-clamps or tyraps.
Damage to the transmission interface harness wiring may result in transmission codes, the PBSS ( pushbutton
shift selector ) not shifting, or transmission failure.
Cause:
Transmission harness routing.
Corrective Action:
As a result, MCI strongly urges owners of the MY2013, MY 2014, MY 2015, MY 2016 and MY2017 J4500 model
coaches listed in this bulletin to implement the steps in this procedure as soon as possible.
66554
66648 to 67895
67897 to 67967
67969
67971 to 67975
67977 to 67980
67982 to 67991
67993 to 68046
68049 to 68058
68060 to 68065
68072 to 68080
Service Bulletin No. 445
Date Mar. 24, 2017
Page 2
Parts
Qty.
New P/N
Description
1
26-07-0125
Kit, Transmission Harness Routing
Kit Contents are:
3
07-08-9052
Bracket, Transmission Harness
1
13-11-1387
Bracket, Transmission Bracket
2
07-08-4525
Tie Base, Panduit, TMEH-S10-C100
3
07-08-4526
Tie Base, Panduit, TM3S8-C100
2
07-08-4527
Cable Tie, Heavy Duty, 9 inch
2
07-08-4535
Wrap, Heavy Duty, Bl., 3 inch
2
19-02-6035
DIN9021B, A2/M5
3
19-1-586
Screw, #8-32 x 0.75, Cross, SST
2
19-1-825
Capscrew, Hex, 10-24 x 7/8
3
19-11-1011
Tyrap, Cable, Heavy Duty, 8-4
3
19-2-19
Washer, #8
3
19-2-73
Washer, Lock, #8, Steel
3
19-3-111
Nut, Hex, #8-32, Stainless Steel
2
19-3-228
Nut, Hex, w/Washer, #10-24 UNC
4
19-11-1845
Plug, Cavity
1
19-11-3078
Cable, Double Loop
1
19-01-1536
Capscrew, 1/2-13 x 1.50
1
19-03-0755
a/r
Nut, Flg, 1/2 -13
Loctite, 242
Service Procedure:
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
If the steps in this procedure are performed over a pit, chock the tires. Position the ENGINE RUN
and ENGINE START switches on the engine compartment remote control box to the OFF
position. Allow enough time for components to cool down.
If the steps in this procedure are performed with the coach on a lift, dump the air from the tag
axle suspension and raise coach to desired height. Position safety stands underneath the coach
in only the specified locations shown in Section 3F in the MCI J4500 Maintenance Manual ( as
shown in Figure 1 of this document ). Support the tag axle.
Ensure that the coach is securely supported before attempting work underneath the coach.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 3
1. Drive the coach over a pit, or use a lift to access the transmission harness.
2. Turn the main battery disconnect switch to the OFF position.
DO NOT place safety stands in any other location than shown in Figure 1 and Section 3F in the
MCI J4500 Maintenance Manual.
Figure 1. J4500 coach hoisting and safety stands location.
Figure 1 Description
Item
S
Safety Stand ( Primary locations )
J
Jacking Point
H
Hoisting Point
Service Bulletin No. 445
Date Mar. 24, 2017
Page 4
3. Locate the transmission harness connector, behind the roadside, tag axle wheel ( refer to Figure 2 ).
Figure 2. Transmission harness routing.
Visually inspect the transmission harness for:
•
•
•
Corrosion buildup on the internal pins of the transmission harness connector,
Chafing or damage to wire(s) at intersection points with p-clams or tyraps,
Stress on the interface connector.
.
If any of the above are present upon visible inspection, contact the MCI Fleet Support
Technical Center at 1-800-241-2947 for further information.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 5
If the coach is equipped with an Optional engine bay snow pan assembly, remove and retain the
six ( 6 ) capscrews and fender washers from the assembly. Carefully support the weight and
allow the assembly to swivel downwards and hang, supported on the assembly hinge as shown
in Figure 3.
If the coach is NOT equipped with an Optional engine bay snow pan assembly, proceed to Step
4.
3
2
1
Figure 3. Optional engine bay snow pan.
Figure 3 Description
Item
1
Optional engine bay snow pan assembly
2
Mounting hardware, quantity of six (6). Ref. capscrew p/n is 19-1-22, fender washer p/n is 19-2-119.
3
Nut weld, double tab, quantity of six (6)
Service Bulletin No. 445
Date Mar. 24, 2017
Page 6
4. At the forward section of the transmission, locate the transmission harness connector shown in Figure 4.
5. Using a 8 mm socket, loosen the mounting screw from the face of the transmission harness connector.
Carefully pull to disconnect the transmission harness connector ( refer to Figure 5 ).
Figure 4. Transmission harness connector location.
Figure 5. Transmission harness connector removed from the interface port.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 7
6. Visually inspect the transmission harness connector and the transmission interface port for corrosion
buildup on the internal pins ( refer to Figures 6 and 7 )
If upon visible inspection there is corrosion buildup on the internal pins as shown in Figures 6
and 7, contact the MCI Fleet Support Technical Center at 1-800-241-2947 for further information.
Figure 6. Evidence of corrosion on the transmission harness connector pins.
Figure 7. Evidence of corrosion on the transmission interface port.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 8
7. Locate the existing p-clamps shown as Item 1 in Figure 8.
8. Remove and discard the eight (8) existing p-clamps shown in Figure 8, as well as the p-clamps on the
dipstick.
1
1
1
1
3
1
2
Figure 8. Removal of p-clamps from transmission.
Item
Figure 8 Description
1
Remove and discard existing eight (8) p-clamps
2
Front bracket location
3
Rear bracket location
Service Bulletin No. 445
Date Mar. 24, 2017
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TSB/Document ID: SB 445
Replacement Service Bulletin Number:
MFR Communication Date: 2017-03-24
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:AUTOMATIC TRANSMISSION
MFR Component System:
MFR Component Subsystem:
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