NHTSA ID Number: 10152972
Manufacturer Communication Number: SB 466
TSB/Document Date: 2019-02-19
Summary
This Service Bulletin informs affected owners of model year 2018 J4500 model coaches that the potential exists for water intrusion into the remote junction boxes, potentially causing corrosion and possible failure of the electrical connectors and that MCI
will remedy the affected coaches at no cost to the owners.
Service Bulletin No. 466
J-Coach Remote Boxes Rework
MODEL:
J Series
TYPE:
SECTION/GROUP:
Field Change Program
07- Electrical
DATE:
12/07/2018
Customer Complaint:
Motor Coach Industries ("MCI") has become aware that on MY2018 J4500 coaches,
the potential exists for water intrusion into the remote junction boxes, potentially
causing corrosion and possible failure of the electrical connections.
Cause:
Due to the panel door of the remote boxes being flush with the coach exterior, the
boxes are exposed to rain, washing and other forms of splashing water. Inadequate
sealing of the remote boxes allows water to enter the boxes, potentially causing
corrosion build-up and possible switch failure.
Corrective Action:
MCI strongly urges owners of the affected coaches to have the following procedure
performed as soon as possible.
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
To avoid personal injury:
a. Turn the main battery disconnect switch to the OFF position.
b. Ensure that both the front and the rear wheels are chocked.
c. Position the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
d. Allow enough time for components to cool down prior to working in the
engine compartment.
Page 1 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
1.0
Material requirements
Service Kit T07-3598 contains the following parts:
ITEM
1
2
3
4
5
6
7
8
9
10
11
PART NO.
19-02-0438
19-01-2373
19-02-0439
19-02-0440
19-08-0143
19-11-4264
19-11-3493
19-05-0425
19-02-0441
23-02-0123
23-05-0005
QTY U/M
DESCRIPTION
8
EA
#8 SEALING WASHER
8
EA
SST SCREWS FOR DTM
12
EA
#6 SEALING WASHER
8
EA
1/2 SEALING WASHER
1
EA
1/2 SEALING PLUG
1
EA
DEUTSCH HD10 GASKET
2
EA
DEUTSCH L012 GASKET (DTM)
2
EA
DUCKBILL DRAIN VALVE
2
EA
3/8 SEALING WASHER
1
TUBE ADHESIVE - CYANOACRYLATE, CA40, 1OZ
1
TUBE ALCOHOL – ISOPROPYL
2.0 Special Tools
No special tools needed for this installation
Page 2 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
3.0
Removing the RH Rear Service Door “Remote Junction Box” -
Open the curb side rear door of the coach to view the remote junction box
Disconnect the connector EJ-X189A on the rear of the box
EJX189A
Page 3 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
Raise the toggle switch cover and remove the toggle switch nut, then remove the
four screws on the front plate holding the box.
REMOVE NUT
& SWITCH
COVER
REMOVE FOUR
SCREWS
TOGGLE
SWITCH
Remove the box from the rear of the engine compartment rear door.
Page 4 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
3.1
Opening the box
Remove the four cover screws, washers and open the cover. Remove the four
locknuts on the EJ-X189 bulkhead connector.
REMOVE
4
SCREWS
REMOVE
4 LOCK
NUTS
Remove and discard the four screws and pull out the connector from the rear cover.
REMOVE &
DISCARD
4 SCREWS
Page 5 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
3.2
Installing the rear connector gasket
Stretch the Deutsch gasket 19-11-3493 (VPN DT12-L012-GKT) over the connector,
taking care not to tear the gasket. Push the connector and gasket against the cover,
then Install the four new stainless steel screws 19-01-2373 to secure the connector.
4 SCREWS
19-01-2373
GASKET
19-11-3493
Install the #6 sealing washer 19-02-0439 onto the stainless steel screws. Then
reinstall the existing locknuts onto the stainless steel screws.
#6 SEALING
WASHER
19-02-0439
Page 6 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
3.4
Installing the front connector gasket
Remove the four screws and locknuts and pull out the diagnostic connector EJ-X52
from the enclosure.
REMOV
E
4
SCREW
S
Stretch the Deutsch gasket 19-11-4264 (VPN HD10-9-GKT) over the connector,
taking care not to tear the gasket. Press the connector and gasket against the
cover. Then reinstall the four screws.
GASKET
19-11-4264
(VPN HD10-9GKT)
Page 7 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
Install the #6 sealing washer 19-02-0439 onto the original screws and reinstall the
four original lock nuts. Use a screwdriver or similar rod with a small diameter to help
guide the washer onto the screw.
o Use a screwdriver or similar rod with a small diameter to help guide the
washer onto the screw
USE
SCREWDRIVER
AS A GUIDE TO
PLACE THE
WASHER OVER
THE SCREW
EXISTING LOCK NUT
#6 SEALING
WASHER 19-02-0439
3.5
Installing the switch sealing washers
Remove one nut and lock washer from one of the four switches. Then remove a
switch and insert a 1/2" sealing washer 19-02-0440 onto the shaft.
REMOVE NUT &
LOCK WASHER
1/2” SEALING
WASHER 19-02-0440
Page 8 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
Insert the switch back into the enclosure and re-assemble the lock washer and nut
onto the switch as shown below:
1/2” SEALING
WASHER 19-02-0440
LOCK
WASHER
AND NUT
SIDE VIEW
(REFERENCE)
Repeat the previous steps for the remaining switches.
Page 9 of 22
Service Bulletin No. 466
J-Coach Remote Boxes Rework
3.6
Installing the “Duckbill”
Drill an 11/16” hole in the bottom center of the box making sure to avoid the LED
lamp and wires by using a drill-stopper, pipe or similar.
Deburr any rough edges of the hole and remove all metal shavings in the enclosure.
USING A DRILLSTOP OR
SIMILAR, DRILL
A 11/16” HOLE AT
CENTER OF
BOX
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TSB/Document ID: SB 466
Replacement Service Bulletin Number:
MFR Communication Date: 2018-12-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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