Date: February 7, 2018

SERVICE BULLETIN
Service Bulletin No.: 2017-0018
Product Models Affected:
Aero Elite Ford 2xx-series
Aero Elite Ford 3xx-series
Aero Elite Navistar 2xx-series
Aero Elite Navistar 3xx-series
Aerotech Ford 2xx-series
Aerotech Chevy 2xx-series

Aerolite Ford 1xx-series
Aerolite Ford 2xx-series
Aerolite Chevy 1xx-series
Aerolite Chevy 2xx-series

FORM Rev 2017-0323

Purpose:
Seal water leak path at top of wheelchair door and ensuring operational functionality of the
wheelchair frame/door assembly.
Tool(s) / Equipment Required:
Screwdriver, Phillips 2 or 3
Drill
Drill Bit, 3/16-inch diameter
Safety Glasses (PPE)
Dust Mask (PPE)
Weld – Helmet/Face Shield (PPE)
Weld – Leathers and Gloves (PPE)
Part(s) / Material Required:
Description
2.00 x 48.00 inch Plywood ¾ BCX
1.50 x 48.00 inch 14 GA CRS Strap
2.00 x 5.75 inch Plywood ¾ BCX
1.50 x 8.00 inch 14 GA CRS Strap
2.00 x 70.00 inch Plywood ¾ BCX
1.50 x 70.00 inch 14 GA CRS Strap
Sikaflex 252
Screw, SMS 14 x 1.50 PH PHIL SS W
Washer, Nylon 5/32 x 3/8
Screw, TEK #6 X 1 BLG PHIL ZINC
Metal Gusset Plate

Sanding Disk
Sanding Block
Plastic Putty Knife
Flat Pry Bar
Steel Wool
Wire Brush
Welder

Quantity
1
1
1
1
1
1
As Required
22
22
9
2

Part Number
010670-038
N/A
010670-015
N/A
010670-037
N/A
E52631
0035634
0024025
0019373
0034831

General:
1. Inspect the wheelchair door frame for cracks in the metal.
 If there are no cracks evident in the metal door frame, proceed to the Door Frame
Preparation. Then proceed to the Interior Frame Support Procedure.
 If there are cracks evident in the metal door frame, proceed to the Door Frame
Preparation. Second, complete the Door Frame Gusset Installation Procedure. Last,
complete the Interior Frame Support Procedure.
2. Disconnect battery(ies), PCM/ECM Modules, and other electrical device connections as
described in the Ford Service Manual for welding on the chassis.
3. Reconnect battery(ies), PCM/ECM Modules, and other electrical device connections as
described in the Ford Service Manual for welding on the chassis only after completing all
weld process operations.
Procedures:
Door Frame Preparation
1. Remove interior padding at the top and right side of the wheelchair door. Handle with care,
these parts will be reused. Reference Figure 1.

Figure 1
2. Remove exterior wheelchair door screws at the top and the left side (rearward side of
vehicle) of the wheelchair door. Discard the screws. Reference Figure 2.

Figure 2
3. Remove the one (1) piece of wood at the top of the wheelchair door, and two (2) pieces of
wood to the right side of the wheelchair door. Discard pieces of wood. Reference Figure 3.

Figure 3

Interior Frame Support
1. Assemble the 1.50 x 48 inch 14 GA CRS Strap to the 2.00 x 48.00 inch Plywood using four
(4) of the 0019373 screws so that one (1) long edge of each component will butt against the
door frame.
2. Install the 48.00 inch Plywood/Strap Assembly across the top of the wheelchair door with
plywood facing the interior of the vehicle. Hold the Plywood/Strap assembly in place and
drill a 3/16-inch diameter hole through the Strap from the exterior of the vehicle. Install the
new Screw and Washer from the exterior of the vehicle through the Strap. Tighten screws
until snug. Do not overtighten. Reference Figures 4 and 2.
3. Assemble the 1.50 x 70 inch 14 GA CRS Strap to the 2.00 x 70.00 inch Plywood using three
(3) of the 0019373 screws so that one (1) long edge of each component will butt against the
door frame.
4. Install the 70.00 inch Plywood/Strap Assembly on the right side of the wheelchair door with
the plywood facing the interior of the vehicle, starting the Assembly at the interior lower right
corner of the wheelchair door. Hold the Plywood/Strap Assembly in place and drill a 3/16inch diameter hole through the Strap from the exterior of the vehicle. Install the new Screw
and Washer from the exterior of the vehicle through the Strap. Tighten screws until snug.
Do not overtighten. Reference Figures 4 and 2.
5. Assemble the 1.50 x 8 inch 14 GA CRS Strap to the 2.00 x 5.25 inch Plywood, centering the
length dimension of the plywood on the length dimension of the strap, using two (2) of the
0019373 screws so that one (1) long edge of each component will butt against the door
frame.
6. Install the 8.00 inch Plywood/Strap Assembly on the right side of the wheelchair door with
the plywood facing the interior of the vehicle, starting at the top right corner of the installed
over-wheelchair door Strap. Hold the Plywood/Strap Assembly in place and drill a 3/16-inch
diameter hole through the Strap from the exterior of the vehicle. Install the new Screw and
Washer from the exterior of the vehicle through the Strap. Tighten screws until snug. Do
not overtighten. Reference Figures 4 and 2.

Step 5
Step 7

Step 9

Figure 4
7. Seal around perimeter of wheelchair door frame using Sikaflex 252. Reference Figure 5.

Figure 5

8. Reinstall the interior pads, over top of wheelchair door and to the right side of the wheelchair
door, using the take-off pads and hardware. Reference Figure 6.

Figure 6

Door Frame Gusset Installation
1. Scrape away paint in the corners of the inside of the entry door using the steel wool and
wire brush. The area removed should be 4 inches down by 4 inches in. Remove all debris
and ensure there is a smooth finish.
2. Tack weld two metal gusset plates, 0034831, in place in the upper corners of the door
frame, behind where the door will mount.
Caution:
Protect the fiberglass wall material. Welding the metal gusset plates in place
while the door frame is assembled to the fiberglass may cause the fiberglass
to discolor or show burn marks from weld spatter.
3. Weld along the cracks ensuring good filler material fusion to the base material, and smooth
weld.
4. Weld two metal gusset plates, 0034831, in place in the upper corners of the door frame,
behind where the door will mount, and smooth all welds. Reference Figure 7.
5. Spray welds with corrosion inhibitor paint. Then paint to match door frame, as necessary.

Figure 7 Front side, weld metal gusset plate in place.

6. Proceed to Interior Frame Support procedure.
Contact Information:
REV Bus Group - Salina Customer Service, 1655 Wall Street, Salina, KS 67401; or by calling
(785) 827-1033 / (800) 955-9086; or by Email: [email protected]; or by Fax: (785)
827-3017.