INSTRUCTION TO SERVICE
ITS: 58599
SECTION:

203

FRONT SUSPENSION

WRITTEN BY:

Michael Rooney

SUBJECT:

Retrofit “D” shaped anti sway bar mounting bushings and hardware.

ITS58599
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
THIS DOCUMENT AND THE CONTENTS DISCUSSED HEREIN ARE THE CONFIDENTIAL AND
PROPRIETARY INFORMATION OF NEW FLYER INDUSTRIES CANADA ULC AND NEW FLYER OF AMERICA
INC. AND ARE DISCLOSED BY NEW FLYER IN CONFIDENCE. THIS DOCUMENT AND THE CONTENTS
HEREIN ARE NOT TO BE DISCLOSED BY THE INTENDED RECIPIENT WITHOUT THE PRIOR WRITTEN
AUTHORIZATION OF NEW FLYER. ANY UNAUTHOIZED DISCLOSURE, REPRODUCTION OR OTHER
DISTRIBUTION OF THIS DOCUMENT OR INFORMATION IS STRICTLY PROHIBITED AND MAY RESULT IN
ACTION BEING TAKEN AGAINST THE PARTY MAKING THE UNAUTHORIZED DISCLOSURE. THIS
DOCUMENT AND ALL COPIES HEREOF MUST BE RETURNED TO NEW FLYER UPON REQUEST.

PROCEDURE:
1. Open the access door at the curbside rear of the bus and locate the High Voltage Interlock Switch and Battery
Disconnect switches. Figure 1.
2. Disconnect and lock out the High Voltage Interlock Switch. Figure 1.
3. Rotate the Battery Disconnect Switch to the off position. Figure 1.

Battery Disconnect Switch

High Voltage Interlock Switch

Figure 1: Electrical Disconnect Switches.

4. Raise coach in accordance with the New Flyer Service Manual.
5. Locate the front anti-sway bar mounts and bushings.
a.

Remove the two 5/8” bolts that hold the curb side anti-sway bar mount bearings in place.

b.

Remove the bearings and the bushings and spacers.

c.

Remove the two 5/8” bolts that hold the street side anti-sway bar mount bearings in place.

d.

Remove the bearings and the bushings and spacers.

e.

Lower the anti-sway bar down out of the way.

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Remove bearings, bushings
and hardware.

Figure 2: Existing Anti-Sway Bar Mounts and Bushings (Curbside Shown).
6. Bolt the new mounting bracket NF P/N 736363 to the original anti-sway bar mount on the curb side and the
new mounting bracket NF P/N 730078 to the anti-sway bar mount on the street side using two bolts NF
10B10032 and two washers NF P/N 20W10000 and a girdle NF P/N 565103 on each bracket.
a.

Using the two inboard holes on each bracket as a template, mark drilling locations on the chassis tube
then remove the brackets and set them aside for reinstallation later.

b.

Drill two 0.531” dia (17/32) holes through both sides of the chassis tube. Take care to drill perpendicular
to the chassis tube.

c.

On the back side of the chassis tube only, enlarge the holes to 1.00” dia.

Mounting Brackets
Mark Drilling
Locations

Girdle

Figure 3: Brackets Mounted to Mark Drilling Locations.
7. Reinstall the mounting brackets as before using Never Seize NF P/N 5928660 on the bolt threads.
a.

Insert Sleeves NF P/N 730549 from the backside of the chassis tubes.

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b.

Install four Bolts NF P/N 10B08064, four Washers NF P/N 20W08000 (under bolt heads), four Nuts NF
P/N 40N08000 and four Washers NF P/N 739801. Use Never Seize NF P/N 5928660 on the bolt
threads.

c.

Torque the two outer bolts on each mounting bracket to 170 FT-LB and torque the inner bolts that pass
through the frame member to 80 FT-LBS.

8. Install the sway bar mount bushings NF P/N 670150 on the swaybar using a generous amount of Aquashield
water proof grease NF P/N 584243 on the inside surfaces of the bushings.
9. Raise the anti-sway bar back into position and align the bushings with the mounting brackets. Ensure that the
flat face of the bushing is against the mounting bracket.
a.

Install a bearing block NF P/N 670159 over each mounting bushing.

b.

Secure each bearing block with four bolts NF P/N 10B10072 and four Washers NF P/N 20W10000 using
Never Seize NF P/N 5928660 on the bolt threads. Snug the bolts but do not torque.

c.

Install a Zerk fitting NF P/N 739737 in each bearing block. Ensure that the nipple faces downward.

Zerk Fitting

Bearing Blocks

Bushings

Figure 4: Completed Installation.

10. Lower coach in accordance with the New Flyer Service Manual.
11. Remove the lock and reconnect the High Voltage Interlock Switch. Figure 1.
12. Rotate the Battery Disconnect switch to the on position. Figure 1.
13. Switch the bus on and allow the bus to reach normal ride height then raise the bus with wheel lifts or position
bus over a service pit.
14. Torque the anti-sway bar mount bearing block bolts to 170 Ft-LBS at ride height.
15. If necessary, lower coach in accordance with the New Flyer Service Manual.
16. Remove all tools and debris and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Retrofit “D” shaped anti sway bar mounting bushings and

Men

Hours

1

2.0

Labour Time
M X HR
2.0

hardware.

PARTS REQUIRED
Item

Part Number

1

736363

BRKT – STABILIZER BAR

Qty.
per
Coach
1

2

730078

BRKT – STABILIZER BAR

1

EA

3

10B10032

BOLT – HEX 5/8 UNC X 2.00

4

EA

4

20W10000

HARDENED WASHER – 5/8

12

EA

5

5928660

NEVER SEIZE

0.01

EA

6

730549

SLEEVE – STABILIZER BAR

4

EA

7

10B08064

BOLT – ½ X 4.00

4

EA

8

20W08000

WASHER FLAT HARDENED ½”

4

EA

9

40N08000

NUT – HEX LOCK ½ UNC

4

EA

10

739801

WASHER – 2.00 X .525 X .179

4

EA

11

670150

BUSHING – STABILIZER BAR

2

EA

12

584243

AQUASHIELD - GREASE

0.01

EA

13

670159

BLOCK – STABILIZER BAR

2

EA

14

10B10072

BOLT – HEX 5/8 UNC X 4.50

8

EA

15

739737

FITTING – ZERK 90 DEG

2

EA

16

565103

BLOCK – SWAY BAR GIRDLE

2

EA

Description

Units

Notes

EA

SPECIAL TOOLS REQUIRED
Item
1

Part Number

Description

Qty.
per
Coach

Notes
Units

No Special Tools Required

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