NHTSA ID Number: 10162335
Manufacturer Communication Number: BS4040ER3
TSB/Document Date: 2019-07-08
Summary
Water infiltration and structural weakness
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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Chicago Transit Authority - CTA - Illinois
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PAGE 2 OF 29
SERVICE BULLETIN
SAV.1E.2012MA
BS4040ER3
Follow your internal safety procedures.
PROCEDURE
1.1.
Park the vehicle on an even surface with the transmission in neutral (N) and apply the parking brake. Set the
master control switch to the STOP position (see Figure 1).
Figure 1 - Set the Master Control Switch to the STOP Position
1.2.
Place the battery disconnect switch in the battery compartment in the OFF position and disconnect the
negative cable from the battery terminal (see Figure 2).
Battery disconnect switch
Battery
compartment
access panel
Figure 2 - Place the Battery Disconnect Switch in the Off Position and Disconnect the Battery
PAGE 3 OF 29
SERVICE BULLETIN
1.3.
SAV.1E.2012MA
BS4040ER3
Remove the two screws that retain the bike rack and remove the bike rack (see Figure 1).
Remove two screws
Figure 3 - Remove the Bike Rack
1.4.
Remove the top corner bezel screws and remove the bezel. Remove the three turn signal screws and the
turn signals. Remove the five headlight screws and the headlights (see Figure 4).
Remove screws
Figure 4 - Remove the Bezel, Turn Signals and Headlights
1.5.
Unplug the wiper arm hoses, remove the caps, remove the nuts and remove the wiper arms (see Figure 5).
Remove screws
Figure 5 - Remove the Wiper Arms
PAGE 4 OF 29
SERVICE BULLETIN
1.6.
SAV.1E.2012MA
BS4040ER3
Remove the four license plate screws and the license plate. Remove the two tow plugs (see Figure 6).
Liscence plate
Tow plugs
Figure 6 - Remove the License Plate and Tow Plugs
1.7.
Remove the two reflectors, the seven marker lights and the three signal lights (see Figure 7).
Signal lights
Signal lights
Figure 7 - Remove the Reflectors, Marker Lights and Signal Lights
PAGE 5 OF 29
SERVICE BULLETIN
1.8.
SAV.1E.2012MA
BS4040ER3
Unplug the mirror connections, remove the bolts, remove the mirrors, cut the seal around the mirror brackets
before removing the brackets and clean the remaining sealant on the brackets.
Remove the bolts
Figure 8 - Remove the Mirrors
1.9.
Cut the seal around the camera module, remove the two screws, remove the camera cover, remove the bolts
that hold the camera and clean the module (see Figure 9).
Cut the seal around
the camera module
Remove two screws
Figure 9 - Remove the Camera
PAGE 6 OF 29
SERVICE BULLETIN
1.10.
SAV.1E.2012MA
BS4040ER3
Cut the top and bottom seals along the gutters. Drill through the rivets and remove the rivets, using a punch
and hammer if necessary. Remove and clean the gutters (see Figure 10).
Remove the gutters
Figure 10 - Remove the Gutters
WARNING
In order to avoid injury, ensure that there is no air pressure in the pneumatic circuit.
1.11.
Once the air pressure has been removed from the pneumatic circuit, disconnect the pneumatic hose from
the driver's seat. Disconnect the electric connectors from the seat, remove the seat bolts and remove the
seat (see Figure 11).
Pneumatic connection
Figure 11 - Remove the Driver's Seat
PAGE 7 OF 29
SERVICE BULLETIN
1.12.
SAV.1E.2012MA
BS4040ER3
Loosen the screws on the driver's control panel and tilt the panel away from the window (see Figure 12).
Driver's control panel
Figure 12 - Tilt the Driver's Control Panel
1.13.
From the inside of the driver's side window, remove all window frame screws except the four corner window
frame screws. Install the suction cups on the exterior of the window and hold firmly to keep the window from
falling (two people required). Remove the four remaing window frame screws and use a plastic chisel to peel
the sealant between the window frame and the window. Remove the window, clean the frame and remove
the sealant (see Figure 13).
Driver's side window
Figure 13 - Remove the Driver's side Window
PAGE 8 OF 29
SERVICE BULLETIN
1.14.
SAV.1E.2012MA
BS4040ER3
Unlock the quarter window seals with a plastic chisel and window lubricant. Place suction cups on the exterior
of the window and hold window firmly (two people required). Push gently at the top of the window from the
inside of the bus and remove the window (see Figure 14).
Quarter windows
Figure 14 - Remove the Quarter Windows
1.15.
Unlock the destination sign window with a plastic chisel and window lubricant. Place suction cups on the
exterior of the window and hold firmly while removing the window (2 people required). Clean the window
(see Figure 15).
Destination sign window
Figure 15 - Remove the Destination Sign Window
PAGE 9 OF 29
SERVICE BULLETIN
1.16.
SAV.1E.2012MA
BS4040ER3
Place suction cups on the windshield and unlock the seal around the windshield with a plastic chisel and
window lubricant. Remove the winshield (2-3 people required) and seal, clean the winshield (see Figure 16).
Figure 16 - Remove the Windshield
1.17.
Remove the microphone, phone, phone stand bracket and the driver sun shade. Do not remove the VIN
plates and decals (see Figure 17).
Figure 17 - Remove the Phone and Sun Shade
PAGE 10 OF 29
SERVICE BULLETIN
1.18.
SAV.1E.2012MA
BS4040ER3
Remove the screws on the front right door post capping (see Figure 18).
Figure 18 - Remove the Door Post Capping
1.19.
Remove the two dashboard screws on the street side and the two screws on the curb side and remove the
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TSB/Document ID: BS4040ER3
Replacement Service Bulletin Number:
MFR Communication Date: 2019-06-28
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
MFR Component Subsystem:
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