Spartan Motors USA, Inc.

Technical Service Bulletin

Remove regulator from glass channel in manual
window regulator configurations.

Ensure window down is resting on
window stop.

Manual Window Configuration
FIG. 8-1

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 8 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

5. For view showing front door with door panel removed. Refer to FIG. 9-1.

Front door shown with
door panel removed.

FIG. 9-1

6. While removing the door panels the door latch rods will need to be disconnected. Refer to
FIG. 9-2.

Remove door latch rods
from back of paddle
handle by pressing the
clips off the rods then
slide rods out of clips.
Ensure clips stay in place
on back of paddle handle.

FIG. 9-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 9 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

7. While removing the door panels any electrical wires connected to the door panels such as
power window switches or door lights will need to be disconnected. Reference S-2680-001
Electrical Instruction Addendum.
8. Disconnect all wiring that may go through the door hinge for items such as power mirrors
(removal of mirror may be necessary to access connector for de-pinning), door lights and
power windows. Wire pass through spring(s) will need to be removed and retained for reuse. Refer to FIG. 10-1. Reference S-2680-001 Electrical Instruction Addendum.

Wire pass through spring. Spring
also shown removed.

FIG. 10-1

9. Inspect wires for chaffing and repair/replace any wires where the insulation is worn or not
present. Reference S-2680-001 Electrical Instruction Addendum.

10. Remove and discard the door latch and fasteners. NOTE: two fasteners toward outside of
door utilize nuts to secure the latch to the door frame. Ensure these do not fall into the
doorframe when removing or installing parts. Refer to FIG. 11-1.

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 10 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Torque fasteners to 45 lbf-in.

Remove and discard latch.

FIG. 11-1

11. Inspect the area beneath the latch for a polyurea coating such as Line-X®. Refer to FIG. 12-1.
If such a coating is present beneath the latch, it must be removed prior to installing the new
latch. To remove the coating, mark the area to be removed as shown in figure 12-2. Score the
coating along the boundary with a utility knife. Use a scraper to remove the coating from the
area. Paint may be applied to the area to enhance appearance. Refer to FIG. 12-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 11 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

¾”

6 ¾”

¾”

POLYUREA COATING
(Line-X)

REMOVE COATING FROM THIS AREA THEN
PAINT TO ENHANCE APPEARANCE
FIG. 12-2

FIG. 12-1

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 12 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

12. Inspect the area beneath the latch logic on the inside of the door frame for a polyurea coating
such as Line-X®. Refer to FIG. 13-1. If a coating is present beneath the latch logic (Latch logic
mounting surface), it must be removed prior to installing the new latch. Use a scraper or
similar tool to remove the coating from the area.

VIEW FROM
OUTSIDE DOOR

VIEW FROM
INSIDE DOOR

VIEW FROM
INSIDE DOOR

LOOK INSIDE
DOOR

LATCH LOGIC
MOUNTING
SURFACE

LATCH LOGIC

FIG. 13-1

13. Inspect threaded mounting holes in latch logic for damage. Refer to FIG. 14-1. Replace latch
logic (P/N 0557-EE3-001 LH, 0534-EE3-001 RH) if thread damage is present.

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 13 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

INSPECT
THREADED
HOLES FOR
DAMAGE

FIG. 14-1

14. Install new door latches and fasteners: P.N. 0533-EE3-001, 0533-EE3-002, 0202-BB1-017 and
M06100FNZ. NOTE: two fasteners toward outside of door utilize nuts for mounting. Ensure
these do not fall into the door frame when removing or installing parts. Torque fasteners to
45 lbf-in. Refer to FIG. 15-1, FIG. 15-2 and FIG. 16-1.

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 14 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

INSTALL NEW
FASTENERS AND
TORQUE TO 45 lbf-in.

INSTALL NEW
DOOR LATCH

FIG. 15-1

Control
levers
shown
assembled
in door

FIG. 15-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 15 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Ensure control
levers are
engaged properly
when assembled.
Shown with door
removed for
better clarity.

FIG.16-1

15. Remove the door latch striker: P.N. 0550-EE3-001. Refer to FIG. 16-2

REMOVE LATCH STRIKER
FIG16-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 16 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

16. Inspect the area beneath the latch striker for a polyurea coating such as Line-X®. Refer to FIG.
17-1. If such a coating is present beneath the latch striker, it must be removed prior to
installing the new latch striker. To remove the coating, mark the area to be removed as shown
in figure 17-2. Score the coating along the boundary with a utility knife. Use a scraper to
remove the coating from the area. Paint may be applied to the area to enhance appearance.
Refer to FIG. 17-2

1/4”

4”

1/4”

POLYUREA COATING
(Line-X)

REMOVE COATING FROM THIS AREA THEN
PAINT TO ENHANCE APPEARANCE

FIG. 17-1

FIG. 17-2

17. Replace the door latch striker with P.N. 0550-EE3-001. Install striker snug tight. Final
adjustments will be made after hinge replacement and door positioning. Refer to FIG. 18-1

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 17 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Install new striker per 0764-EE3
print and adjust per striker latch
process 0253-ZZ4.

FIG. 18-1

18. Support the weight of the door in an opened position in preparation for removing the door
hinge. Door weights approximately 150-200 lbs.
19. Once door is supported remove door hinge fasteners. Retain for re-use. Properly dispose of
old hinge and washers. Refer to FIG. 18-2.
Hinge bolt

Existing hinge mounting
washer (.75 OD) properly
dispose of these when
removed

New Belleville washer (.93 OD)
washer P.N. 61200596

FIG.18-2

20. Ensure that bolts and washers are clean and dry then reinstall new door hinge using retained
bolts, new washers, (P.N. 61200596) and (2) reinforcement plates (P.N. 17200723) at each
Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 18 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

front door. No reinforcement plates required for the rear doors. For proper washer
installation Refer to FIG. 19-1, 19-2 and FIG. 20-1.

Hinge Bolt

Hinge

Washer

FIG. 19-1

Add backer plate at
this leaf top and
bottom of door
Add washers at all fasteners
for hinge mounting

FIG. 19-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 19 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Front door showing new
hinge and (2) backer
plates installed.

FIG.20-1

21. Once the hinge is properly aligned the hinge mounting fasteners must be torqued to 11-13
lbf-ft. Refer to FIG. 20-2.

Door alignment should
be .25” to .31” gap
around perimeter.
Paint break line or
pinstripe lined up and
outside of door skin
flush with sides of cab
and front skin

FIG.20-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 20 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

22. Once hinge is changed and door is aligned, any electrical items in the door that were removed
can be re-connected and secured. Reinstall retained wire pass through spring (s) and secure
them. Reference S-2680-001 Electrical Instruction Addendum.
23. Reinstall retained door panels. During door panel re-installation, window regulator and door
latch rods must be re-connected. Ensure rod clips are clipped onto rods securely. Refer to
FIG. 21-1.

View of back of paddle
handle showing rod
connections

Rod installed through clip snapped
onto rod securely

FIG. 21-1

24. For power window regulator alignment Refer to FIG 22.1.

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 21 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Install these two fasteners loosely
initially during re-installation. For
final adjustment window needs
to be rolled down approx. . . . 6”
then two fasteners to be fully
driven, seated and not stripped.
This will allow the regulator to go
up and down smoothly.
Power window configuration shown

FIG. 22-1

25. New door seals will need to be applied to new door hinges. Refer to FIG. 22-1, FIG. 23-1, FIG.
23-2, FIG. 24-1 and FIG. 24-2.
Hinge door
side

Hinge cab side

35” seal

36” Seal
For proper door hinge seal
installations make sure all
surfaces are cleaned with
isopropyl alcohol before
applying seals.

FIG.22-2

Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 22 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

Front door seals

FIG. 23-1

Top of door

“A” seal length

“B” seal length

“C” seal length

Inside of door

Rear door

FIG.23-2
Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 23 of 24

QUA-FR-0290
Rev: 3.0

Spartan Motors USA, Inc.

Technical Service Bulletin

FIG.24-1

Top of door

Rear door seals

FIG.24-2

26. Once door panel is re-installed and all fasteners are tightened the door check strap can be
re-installed. Door check strap fasteners to be torqued to 80-90 lbf-in.
27. At this time final adjustments to door latch striker can be made per striker/latch process
0253-ZZ4.
28. END
Service Bulletins are intended for use by Professional Technicians only. They are written to guide Professional Technicians in performing service to
vehicles of specific nature in conjunction with industry standards. Professional Technicians should be appropriately trained on industry standards and
have the tools and equipment to perform procedures safely and properly.

17005

Page 24 of 24

QUA-FR-0290
Rev: 3.0