NHTSA ID Number: 10128756
Manufacturer Communication Number: LI4223E
TSB/Document Date: 2018-02-12
Summary
Repair procedure for cracks reoccurring on the flooring above the rear axle
Elliot Lake - Ontario
L148
04-01
04-02
L82U143000162
L82U343000163
2
First Transit Inc. (ref. L173)
L144
—
—
L82U543000049
L82U543000049
1
Grand River Transit - GRT - Ontario
L145
2400
2417
L82U143000114
L82U143000131
18
Grand River Transit - GRT - Ontario
L161
2418
2433
L82U643000254
L82U843000269
16
Guelph - Ontario
L115
169
176
L82P933000080
L82P133000087
8
Guelph - Ontario
L132
177
179
L82P443000019
L82P243000021
3
Guelph - Ontario
L167
180
182
L82U943000250
L82U243000252
3
Regina - Saskatchewan
L166
598
603
L82U453000027
L82U853000032
6
Regina - Saskatchewan
L183
604
608
L82U853000046
L82UX53000050
5
Strathcona County Transit - Alberta
L177
921
923
L82U953000024
L82U253000026
3
Thunder Bay - Ontario
L131
137
141
L82SX43000014
L82S743000018
5
Timmins - Ontario (ref. L189)
L144
—
—
L82U343000048
L82U343000048
1
Walt Disney World - Florida
L113
4862
4884
L82P623000343
L82P523000365
23
Walt Disney World - Florida
L118
4885
4885
L82P723000366
L82P723000366
1
Walt Disney World - Florida
L174
174-1
174-1
L82U553000005
L82U553000005
1
PAGE 3 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI4223E
Follow your internal safety procedures.
CAUTION
See Section 12: INTERIOR FURNISHING and Section 01: BODY in the Nova
LFS Maintenance Manual for
more information on safety precautions before performing the following procedure.
NOTE
Please contact the respective Nova Bus Service Representative for any queries related to repair.
PROCEDURE
LEVEL 1: INSPECTION FOR CRACKS
1.1.
Park the vehicle on an even surface with transmission in neutral (N) and apply the parking brake.
1.2.
Set the Master control switch in the STOP position (see Figure 1).
Master control switch in
STOP position
Figure 1 - Master Control Switch in STOP Position
Before starting any work on the vehicle, make sure the vehicle is completely and securely stationary.
Disconnect the starting circuit on the control box at the rear of the vehicle and place the battery disconnect
switch in the OFF position.
1.3.
Raise the vehicle.
CAUTION
VEHICLE HOISTING. Follow your internal safety procedures. Use appropriate safety equipment for your
protection. See section 18 : HOISTING AND TOWING in the Nova LFS Maintenance manual for more information.
PAGE 4 OF 16
INFORMATION LETTER
1.4.
SAV.1E.2012MA
LI4223E
Install the jacking supports under the vehicle to secure the working area.
NOTE
See section 05: REAR SUSPENSION for exact information on removal of rear axle.
1.5.
Remove and retain the rear axle.
NOTE
See section 10: TRANSMISSION AND CONTROL for exact information on removal of drive shaft.
1.6.
Remove the drive shaft from the transmission. Retain the drive shaft and the hardware.
1.7.
Remove all the mud flaps located in front of the rear axle. Retain the mud flaps and hardware.
1.8.
Remove and retain the air spring located in front of the rear axle.
1.9.
Disassemble the fuel and tire lines from the support and install plugs to remove them from the area to be
welded.
1.10.
Locate the area to be inspected as shown (see Figure 2).
WheelHouse
Street Side
Underside of the
Reinforcement welded area
Figure 2 - Inspection for Cracks Underneath the Street Side Wheelhouse
PAGE 5 OF 16
INFORMATION LETTER
1.11.
SAV.1E.2012MA
LI4223E
Inspect the area for cracks.
1.11.1. If only one crack is present, proceed to LEVEL 2 (step 2.61 onwards).
1.11.2. If more than one crack is present, proceed to LEVEL 2 (step 2.1 onwards).
1.11.3. If no cracks are found, proceed with the following steps.
1.12.
Install the retained air springs and hardware.
1.13.
Install the retained mud flaps with the retained hardware.
NOTE
See section 10: TRANSMISSION AND CONTROL for exact information on installation of drive shaft.
1.14.
Install the drive shaft on the transmission
NOTE
See section 05: REAR SUSPENSION for exact information on installation of rear axle.
1.15.
Install the retained rear axle with the retained hardware.
1.16.
Remove the jacking supports from beneath the vehicle.
1.17.
Lower the vehicle.
1.18.
Set the battery disconnect switch in the battery compartment to ON position.
1.19.
Place the Master control switch in ON position.
1.20.
The vehicle may be returned to service.
PAGE 6 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI4223E
LEVEL 2: RE-WELDING THE CRACKS, INSTALLATION OF BRACE, FLOOR PLYWOOD AND
FLOOR COVERING
CAUTION
Before performing any welding operation on the vehicle,as well as plasma cutting, sensitive electronic
componentsmust be disconnected to prevent damage. Once welding hasbeen completed, the components
must be reconnected in the reverse order. See Section 01: STAINLESS STEEL CHASSIS in the Nova LFS
Maintenance Manual for more information on safety precautions before performing the following procedure.
2.1.
Apply degreaser onto the crack surface to remove undercoating.
2.2.
Apply penetrating liquid to trace the ends of the cracks.
2.3.
Drill a 3/16 inch to 1/4 inch hole at each end of the crack in order to stop the crack from growing.
2.4.
Weld the crack from one end to the center and resume welding from the other end towards the center. Make
sure the hole at each end of the crack must be welded.
2.5.
Install the retained air springs and hardware.
2.6.
Install the retained mud flaps with the retained hardware.
NOTE
See section 10: TRANSMISSION AND CONTROL for exact information on installation of drive shaft.
2.7.
Install the drive shaft on the transmission.
NOTE
See section 05: REAR SUSPENSION for exact information on installation of rear axle.
2.8.
Install the retained rear axle with the retained hardware.
2.9.
Remove the jacking supports from beneath the vehicle.
2.10.
Lower the vehicle.
2.11.
Locate the floor covering between the rear wheelhouses inside the vehicle (see Figure 3).
Street side Wheelhouse
Curb Side Wheelhouse
Figure 3 - Typical Location of Floor Covering
PAGE 7 OF 16
INFORMATION LETTER
SAV.1E.2012MA
LI4223E
NOTE
See section 12-400: FLOOR COVERING for exact information on removal of floor covering.
2.12.
Mark the outline of the area to be repaired with a washable marker as shown (see Figure 4).
1000 mm
Rear Step
Floor Covering to
be Retained
Repair Area where Floor
Covering has to be Removed
Front of Step
Street Side
Curb Side
Seam
Floor Covering to be
removed
Figure 4 - Typical Location of Repair Area
2.13.
Cut a piece of new floor covering to the fit the repair area.
2.14.
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TSB/Document ID: LI4223E
Replacement Service Bulletin Number:
MFR Communication Date: 2018-01-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System:
MFR Component Subsystem:
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