Number:
Model:

FS-2018-01

Date:__January 5, 2018

29’, 35’ & 40’ Low Floor Buses

Model Years:

1997- 2016

Approved:
Robert L. Birdwell, Executive Director
Quality Control & Field Service

Subject: Steering Gear Mounting Plate Replacement Procedure
This is a reissue of a portion of FS-2016-06, (Pages 7 through 13).
The reason for this Field Service Bulletin is that due to varying bolt shoulder length, and
tolerance variations, there is a possibility that the bolts used to mount the steering gear
mounting plate to the chassis could ‘bottom out’ prior to full engagement against the
plate.
We are therefore modifying the bolt kit available for buses that haven’t had the steering
gear mounting plate replaced, and releasing another kit for buses that have had the
steering gear mounting plate replaced.
54-74537-002 total hardware kit for buses that haven’t had the plate replaced.
54-74537-001 bolt replacement kit for buses that have had the plate replaced.
The difference is the length of the ½”-20 Grade 8 bolts from 2-1/2” to 2-1/4”.
The significant changes from FS-20106-06 are highlighted in yellow.
If you have any questions, please contact GILLIG Field Service at 1-800-264-5073, or email
WarrantyParts@gillig.com.

RLB:rlb
GILLIG, LLC
451 Discovery Drive
Livermore, CA 94551
(800) 735-1500
(510) 785-1500
BB@Gillig.com

FS-2018-01
Page 2

GILLIG Low Floor Bus
Steering Gear Mounting Plate Replacement Procedure

Overview Instructions
1.
2.
3.
4.
5.

This procedure covers the replacement of the existing 3/8” thick steering gear
mounting plate with a 3/4” thick mounting plate on all GILLIG Low Floor Buses.
A vehicle lift or pit is required to complete this procedure.
Refer to your GILLIG Service Manual for any procedures not covered in this
document.
Always reinstall the same steering gear that was removed, unless the gear
needs to be replaced.
Do not make any adjustments to the axle stop bolts during this procedure. If
any adjustments are made, the steering gear poppets may require possible readjustment per TRW Service Bulletin # TAS-101.

Special Tools & Materials Required
1.

2.
3.
4.
5.
6.
7.
8.
9.

Torque wrench(s)
A. Min Torque Required is 90 ft-lbs.
B. Max Torque Required is 445 ft-lbs. (with Anti Seize)
Lifting fixture for the Steering Gear and Plate
Pullers and wedge tools to remove pitman arm and draglink
Hose caps or plugs for sealing disconnected hydraulic fittings
#8, #10, and #12 Fittings
Bostik Never-Seez Anti-Seize, Regular Grade (K=.13)
3/4-in drive breaker bar
4-6 ft ladder if using a lift
Pry bar
White, Green or Yellow Paint Pen

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Page 3

Parts Required
Application

Part Number

Description

29ft Stainless
Steel Low Floor w/
Drum Brakes

05-74397-000

Plate, Steering Gear
Mounting, 29 SSLF
-OR-

1

05-63059-000
or 05-50256000

29ft Stainless
Steel Low Floor w/
Disc Brakes

05-74344-000

Plate, Steering Gear
Mounting, 76000 LF
-OR-

1

05-63058-000

1

05-50265-000

29ft Carbon Steel
Low Floor w/
Raised Gear

05-74685-000

Plate, Steering Gear
Mounting, Mild Steel LF,
Raised Gear
-OR-

QTY Replaces P/N

35 and 40ft
Stainless Steel
Low Floor

05-74344-000

Plate, Steering Gear
Mounting, 76000 LF
-OR-

1

05-63058-000
or 05-45365000

29, 35, and 40ft
Carbon Steel Low
Floor

05-74636-000

Plate, Steering Gear
Mounting, Mild Steel LF
-AND-

1

05-36841-000

1

N/A

Hardware Kit
(required for all
plate replacements)

54-74537-002

Kit, Hardware, 3/4THK
Steering Gear Plate

Removal of Old Steering Gear Plate
1. Use the appropriate personal protective equipment for under-bus maintenance and use of
cleaner/de-greaser agents.
2. Safely place bus on vehicle lift or pit. Place front wheels in straight ahead position. If on a
lift, do not yet lift the bus until Step 3, Battery Removal, is completed.
3. Ensure parking brakes are applied, engine off, and battery disconnect switch is in the OFF
position.
4. Disconnect and remove the battery located on the upper battery tray. Start by removing the
negative/chassis ground lead before removing the positive lead. Refer to your GILLIG
Service Manual for additional details for battery removal. Note: It is not necessary to remove
the battery on the lower tray. Removal of the upper battery will allow access to the gear side
of the plate. Always lift the battery with handles or proper lifting devices.

FS-2018-01
Page 4

5.
6.
7.
8.

9.
10.

11.
12.

13.

14.

15.
16.

If using a lift, raise the bus to a sufficient height to reach the steering gear plate and all plate
mounting bolts.
Thoroughly clean off all outside dirt and grease from the steering gear, especially around the
hose connections, with a suitable cleaner/de-greaser.
Remove the draglink from the pitman arm.
Disconnect the intermediate shaft from the steering gear by loosening the universal joint pinch
bolt and sliding the intermediate shaft free from the steering gear. Do NOT hammer or pound
the universal joint coupling off the steering gear input shaft, as this can cause damage to the
input shaft and/or internal damage to the steering gear.
Disconnect clamp securing the air line adjacent to the steering gear.
Loosen the 5 steering gear mounting bolts shown in Detail B but do not remove the hardware.
Note: it may be necessary to rotate the pitman arm clear of the lower, 7/8” bolt. If necessary,
rotate it just enough to provide clearance to break the bolt loose. Excessive rotation may
require resetting the steering gear poppets.
Place the lifting fixture to hold the steering gear and mounting plate.
Remove the 10 bolts holding the steering gear mounting plate to the bus chassis. Note:
Access is provided to the heads of the steering gear plate mounting bolts through the battery
box where the upper battery was removed. The use of a swivel joint and socket extensions
may be useful. If using a lift, a 4-6 ft ladder can be used to aid in access through the cut-out in
the back of the battery box. A second person should secure the nuts on the backside of the
plate to prevent them from spinning.
Disconnect power steering supply and return hoses at steering gear. Cap both hose ends and
steering gear fittings with plugs to prevent contamination and excessive drainage of hydraulic
fluid. Note: It may be useful to place a bucket or absorbent material under the steering gear
when disconnecting the hydraulic lines for spill containment.
Lower the steering gear and mounting plate assembly from the chassis. Take special caution
to avoid damaging surrounding parts, lines, fittings, or other equipment. In order to avoid
these parts, the steering gear plate may need to be slightly rotated prior to lowering out of the
chassis.
Use a suitable device (forklift, hoist, etc.) to remove the steering gear and plate from the fixture
and place on a workbench or ground.
Remove the Pitman arm from the steering gear. Note: The output shaft and Pitman arm have
alignment marks stamped into them. These may be hard to see, especially if they are
dirty/greasy. If the alignment marks are not easily seen, it may be useful to mark the
alignment with an alternative method, like a paint pen, prior to removal. The Pitman arm will
be reinstalled in the same position at the end of this procedure. See Detail A.

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Page 5

Note:
A.
B.

C.

17.
18.
19.
20.

A chisel will help to loosen the pitman arm from the steering output shaft. Use a
puller if you cannot remove the pitman arm by hand.
If using a chisel to spread the pitman arm boss to loosen the pitman arm for
removal, keep a firm grip on the chisel. Failure to do this may result in the chisel
flying loose and causing injury. Never leave the chisel wedged in the pitman arm
boss. If you cannot remove the pitman arm from the shaft with a chisel and
your hands, remove the chisel from the pitman arm and use a puller.
Once the draglink is removed do not allow the input shaft on the steering gear to rotate
more than 1.5 input shaft revolutions from straight ahead position. Rotating the input
shaft more than 1.5 rotations from straight ahead with the draglink removed could
disrupt the poppet setting set at initial installation. The steering gear is in the straight
ahead position when the timing marks on the end of the housing trunnion and the
sector shaft are aligned, as shown in Detail A.

Unbolt the steering gear from the mounting plate.
Clean the steering gear with a rag moistened with a suitable cleaner or de-greaser, then
inspect the steering gear for any signs of wear or damage.
Clean off the mating surfaces of the steering gear to prepare for mounting to the new 3/4”
thick mounting plate.
Remove all existing steering gear plate fasteners from the chassis to mount the plate. These
will be replaced. Note: It may be necessary to remove the clamp securing the coolant/heater
lines for proper access to remove the fasteners.

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Page 6
Installation of New Steering Gear Plate
21.

Install the steering gear in reverse order on the new 3/4” thick steering gear mounting
plate using anti-seize on all mounting fasteners. See Detail B for installation details and
torque values. Do not torque mounting fasteners until Step 28, after re-installation of plate
into chassis.

22.

Clean off the steering gear output shaft and clean the spline and bolting surfaces on the
Pitman arm. Re-install the pitman arm to the output shaft. Ensure the alignment marks are
properly aligned, as shown in Detail A. Apply anti-seize to the new pinch bolt, install, and
torque to 260-280 ft-lbs. See Detail C for hardware details.

FS-2018-01
Page 7
23.

Apply anti-seize to new plate mounting bolts, insert loosely into chassis mounting holes,
and reinstall/re-secure coolant lines back into place. See Detail D for installation details.

24.
25.

Mount the new steering gear plate with steering gear into the lifting fixture.
Using the lifting fixture, reinstall the steering gear and plate assembly in the chassis.
Take special caution to avoid damaging surrounding parts, lines, fittings, or other
equipment. In order to avoid these parts, the steering gear plate may need to be slightly
rotated prior to reinstalling into the chassis.
Remove fixture and torque plate mounting bolts (Detail D) to 90 ft-lbs.
Verify all mounting plate mounting bolts are properly torqued and apply torque seal.
Torque steering gear mounting bolts from Step 21 and apply torque seal.
Using a white, yellow or green paint pen, mark the plate with the date completed in an
area suitable for visual inspection.
Clean off the draglink ball joint taper and threaded section and clean off the mating taper
in the pitman arm. Re-install the draglink to the Pitman arm and torque the nut to 225
ftlbs. Install a new cotter pin. Anti-Seize is not required at this connection. Note: If
required to align castle nut with cotter pin hole, apply additional torque to castle nut.
PTorque on castle nut not to exceed 400 ft-lbs.
Install the intermediate shaft on the steering gear input shaft. Tighten the pinch bolt to
63-75 ft-lbs. Do NOT apply anti-seize to this pinch bolt. See Detail E

26.
27.
28.
29.
30.

31.

FS-2018-01
Page 8

32.
33.

Remove hose plugs, clean off the hose connection fittings and the hose ends.
Connect the power steering supply and return hoses to the steering gear. See Detail F.

34.

Note: If the clamp securing the coolant/heater lines was removed to allow access, secure
the lines with the clamp and reattach to its original location.
Lower the bus if on a lift. Remove lifts from bus.
Reinstall and connect the battery in the upper tray. Switch the battery disconnect to the
ON position.
Start the engine and check for hydraulic leaks at the steering gear hose connections.
Fix any leaks found and retest.
Top-off hydraulic fluid in reservoir.
With the bus parked and the engine running, slowly make a full right hand and full left
hand turn. Ensure pitman arm and draglink move freely without contacting any of the
hoses, wiring or chassis components.
Bleed the steering gear using the standard bleeding procedure found in the Service
Manual under Hydraulic System section, Bleeding the Hydraulic System.
Test drive the bus to check for proper steering function.
Return the bus to service if it meets all fleet operating standards.

35.
36.
37.
38.
39.

40.
41.
42.

Note: Do not dispose of any cracked plate removed from a bus. Removed plates must be
marked with vehicle identification number, vehicle mileage and date removed from vehicle, then
stored until it can be reviewed by Gillig Field Service personnel.

FS-2018-01
Page 9
Total Hardware Kit (54-74537-002)
For use when plate has not yet been changed

FS-2018-01
Page 9

Bolt Replacement Kit (54-74537-001)
For use when plate has already been changed