8

IS-16900

Instruction Sheet

1

Other parts that may be required:
Part No.
680038

Description

Qty

LOCTITE 243, 50 ML

NOTE
Material can be obtained through regular channels.

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.

NOTE
As a general guideline, use Loctite 243 on all threads except on hardware having Stover type nuts.

NOTE
Prior to starting work, protect the LCD monitor, vehicle flooring around the aisle and steps as well as
the driver’s seat. Do not peel protecting paper off until the end of the procedure.

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Procedure overview.
A reference CAD drawing is available at the end of
this document.
We will start by removing the fore roof panel to
remove an insulation section and get access to the
roof structure. We will also move the driver’s seat
aside.
Then we will proceed to the installation of the
upper and lower post structural reinforcements.
Once this is completed, we will install the post
assembly and transparent protector panel, rear of
the driver’s seat.
Next, we will install the door on the post assembly
and the catch curb side of the aisle.
Finally, the center mirror will be moved higher with
a new bracket.

FIGURE 1 : COMPLETE INSTALLATION OVERVIEW

1. Remove trimming, parcel rack doors and gas
springs to allow removal of carpet ceiling.
2. Remove the first section of carpet ceiling.

FIGURE 2

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3. Cut a section of the foam insulation road side,
next to the monitor.
Remove about 16in wide to create working
space for drilling.

FIGURE 3

4. Install the upper post support #270052.
Refer to Figure 4 for bracket orientation.

FIGURE 4

5. Install bracket #270052 as shown in fig. 5.
Clamp the bracket on the longitudinal roof
channel.
6. Adjust bracket to have bottom face flush
(tangent) with the transversal roof curve. We
want to avoid any warping of the carpet ceiling
section once post support is installed.
7. On the front transverse member, drill 7/32” and
tap 1/4-20 using a thread cutting screw or
tapping tool. Assemble with:
#5001315 Hex cap screw 1/4-20 x 1
8. On the longitudinal member, drill 7/32”.
Assemble with:
#5001697 Hex Cap screw, M6 X 16
#502860 Stover nut, M6

FIGURE 5

9. Place a masking tape on the neighboring roof
section and outline bracket location with a
marker pen.
10. Remove driver seat base mounting bolts and
move the driver’s seat road side.

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11. Remove the aisle step road side fiber cap
located alongside the driver’s seat.
Enlarge the existing trimming as shown in fig. 6

FIGURE 6

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Step preparation.
12. Drill 1/4” in tube using bracket #320952 as a
drilling template.
Assemble with 2x #5001681 M6 x 60mm lg
screw and 2x #502860 M6 Stover nut.
Tighten to

FIGURE 7

FIGURE 8

Protector preparation
13. Install a band of black decal #329671 in the
inside corner of the transparent protector.

FIGURE 9

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14. Pre-install rubber bushings #900251 (2 / hole)
in each hole on the protector.

FIGURE 10

15. Place support #320995 on modesty panel..

FIGURE 11

Protector installation: two team members are
required.
16. Move protector in place and use a center
punch to locate holes.
17. Install with the following hardware
#505539 Bushing
#500805 Flat washer, 7/8” OD
#504399 Snap cap washer
#500855 Flat washer, 7/16” OD
#500637 #8 Pan head screw 1 ½” lg
#504400 Cap
FIGURE 12

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18. Use following hardware on the support
#500805 Flat washer, 7/8” OD
#504399 Snap cap washer
#500855 Flat washer, 7/16” OD
#500637 #8 Pan head screw 1 ½” lg
#504400 Cap, black

FIGURE 13

19. Insert sleeve #329665 inside lower post
bracket #321287 and upper post bracket
#321273.

FIGURE 14

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20. Slide post assembly #320951P in the bases.

FIGURE 15

21. Secure the transparent protector to the post.
Use the following hardware:
#505539 (5X) Bushing
#500805 (5X) Flat washer, 7/8” OD
#504399 (5X) Snap cap washer
#500855 (5X) Flat washer, 7/16” OD
#500436 (5X) #10 Oval head Screw 2” lg
#504400 (5X) Cap, black

FIGURE 16

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22. Locate the lower section of the post.
23. Drill 8mm holes using post base as template.
24. Place rubber pad #321133 under post.
25. Install with the following hardware:
#5001461 Screw, flat head M8 x 40mm lg
#500035 Washer lock split 0.586 in OD
#5001852 Nut, M8

FIGURE 18

FIGURE 17

Two team members are required.
26. Reinstall carpet roof section.

FIGURE 19

27. Locate upper post. Use a level.
28. Also allow clearance for the opening of the
parcel rack door.
29. Drill 7/32” using post base as a template.
Place a drill stop at 40mm (1 ½”) to avoid
drilling through roof.
30. Tap 1/4-20.
31. Use loctite 243 #680038
32. Install #5001315 (4x) 1/4-20 x 1 SS screws.

FIGURE 20

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33. Install #329586 upper protector support
34. Drill 1/8”
35. Install with the following hardware:
#500464 (2X) Countersink washer
#500626 (2X) Oval head screw #8 x 3/4

FIGURE 21

36. Secure protector to panel with the following
hardware:
#900251 (4X) Rubber bushing
#504400 (4X) Cap, black
#500805 (2X) Flat washer, 7/8” OD
#504399 (4X) Snap cap washer
#505539 (2X) Bushing
#5001317 (2X) Pan head screw 8-32 x 1

FIGURE 22

#500764 (2X) Hex nut 8-32
37. Install door on the post hinges. Confirm proper
alignment of holes, drill if required. Use
following hardware:
#900251 (2X) Rubber bushing
#505539 (2X) Bushing
#500805 (2X) Flat washer, 7/8” OD
#504399 (2X) Snap cap washer
#500855 (2X) Flat washer, 7/16” OD
#680038 Loctite 243
#502643 (2X) Pan head screw 8-32 x 1 1/4.
#504400 (2X) Cap, black
#680038 Loctite
#5001783(2X) SHCS M6 x 12mm
FIGURE 23

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**Lower hinge only**
38. Unscrew the three set screws.
39. Re-install set screws with Loctite 243.

FIGURE 24

40. Upper post securement. Use the following
hardware:
#5001783 (2X) SHCS M6 x 12mm
#680038 Loctite
#502634 (1X) Set screw M6 x 6mm

FIGURE 25

41. Lower post securement. Use the following
hardware
#680038 Loctite
#502634 (2X) Set screw M6 x 6mm

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42. Door should not turn open by its own upon a
sudden stop. Adjust pressure balls if required.

FIGURE 26

43. Catch assembly. Do not tighten yet!
#406192 (1X) Catch support
Female catch (comes with door assembly)
#500964 (4X) Washer 0.500 OD
#500767 (2X) Nut 10-24
#500387 (2X) Screw, 10-24 x 3/4

FIGURE 27

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44. Close the door and align female catch.
45. Drill 1/8”
46. Assemble on handrail with following hardware:
#504399 (3X) Snap cap washer
#500855 (3X) Flat washer, 7/16” OD
#500641 (3X) Screw, #8 x 3/4
#504400 (3X) Cap, black

FIGURE 28

47. Close door.
48. Tighten the female catch assembly.

FIGURE 29

49. Door should be open with a force of 50 to 55
pounds.
50. Turn adjusting screw accordingly.

FIGURE 30

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Move center mirror position further up.
51. Dismount and discard original bracket.
52. Fill former holes with:
#509805 (4X) Tapping screw #10 x 1/2 lg

53. Replace by new bracket #400177.

54. Drill 1/8” holes using bracket as template.
Install with:
#509805 (4X) Tapping screw #10 x 1/2 lg

FIGURE 31

FIGURE 32

55. Move the infrared sensor in this location, under
the new mirror bracket.

FIGURE 33

56. Peel protecting paper off the panel and door.

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

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