SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

1

1(19)

First Release

08-12-2019
RADIATOR AND COMPRESSOR DOOR LOWER HINGES REPLACEMENT

Prevost vehicles
DESCRIPTION
On the vehicles affected by this bulletin, the compressor & radiator door lower hinges must be replaced by
new stainless steel units.
MODEL YEAR(S) AND VEHICLES INVOLVED
NOTICE TO SERVICE CENTERS
Verify vehicle eligibility by checking warranty bulletin status with SAP or via ONLINE WARRANTY
SYSTEM available on Service / Warranty tab of Prevost website.
Model

VIN

Fleet Number

X3-45 Commuter
Model Year : 2014 - 2016

The following individual vehicles:
2PCG33495EC735590, 2PCG33498EC735602
and
From 4RKG33497F9737001 up to
4RKG33491G9737299 incl.

From 2490 up to
2789, incl.

This bulletin does not necessarily apply to all the above-mentioned vehicles, some vehicles may have been modified
before delivery. The owners of the vehicles affected by this bulletin will be advised by a letter indicating the Vehicle
Identification Number (VIN) of each vehicle concerned.

MATERIAL NEEDED
Order kit # SP19-301 which includes the following parts:
Part No.

Description

Qty

2810296

Lower hinge (Radiator Door)

1

2810294

Lower hinge (Compressor Door)

1

284607

Door Hinge Bushing

2

502723

Nylon Flat Washer

2

7770478

Radiator door lower hinge reinforcement plate 2in

1

7770484

Compressor door lower hinge reinforcement plate 3in

1

030082

U-Shim 3.175mm

3

5001815

Screw Cap Hex Flanged N500 M6-1.0 X 30 G 8.8

5

502854

Nut Hex N500 M6-1.0

5

430406

Washer, Flat

5

502570

Lock Washer 6.1x11.8x1.6 SS

5

Writer: mg

SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

1

2(19)

Other parts that may be required:
Part No.

Description

Qty

680038

Medium Strength Thread Locker (blue)

1

685353

Torque seal - Tamper proof indicator

1

289150

Compressor door lower hinge arm assy.

1

5001833

Washer, Belleville. Spr

2

5001697

Screw cap hex M6x1.0x16

2

NOTE
Material can be obtained through regular channels.
Tools list:
TOOLS

1. 3/8th inch ratchet

2. 3/8th inch torque wrench

3. 10mm Socket (3/8th)

4. 10mm Wrench
5. Drill

Writer: mg

SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

1

3(19)

6. Drill Bit (3/8th)

7. Drill Bit (1/4th)

8. Flat Chisel
9. 16oz Hammer

10. Cutting Oil

11. Sand paper or Emery Cloth
(medium)

12. Scissor Jack (and V-Block)

13. Hydraulic Bottle Jack

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.

Writer: mg

SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

1

4(19)

PART 1: COMPRESSOR DOOR LOWER HINGE REPLACEMENT
1.

Fully open the vehicle compressor door (rear, curb side of vehicle Fig.1).

FIG.1 VEHICLE COMPRESSOR DOOR

2.

Support the door at its lower edge without applying upward pressure. A scissor jack (or equivalent
lifting equipment) and a V shaped wood block are recommended (Fig.2).

FIG.2 SUPPORTING THE DOOR

Writer: mg

SP19-301

Special Bulletin

3.

Date

Expiration

Release

Page

08.2019

08.2021

1

5(19)

Unscrew, remove & discard the vehicle structure part of the condenser door lower hinge (3X M6
bolts Fig.3)

FIG.3 HINGE PART TO BE REMOVED (COMPRESSOR DOOR)

4.

Remove the two rivnuts (two vertical holes) by drilling them using a 3/8in drill bit (Fig.4).

FIG.4 LOWER HINGE RIVNUTS
Writer: mg

SP19-301

Special Bulletin

5.

Date

Expiration

Release

Page

08.2019

08.2021

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Loosen the battery tray to allow the installation of the reinforcing plate.

-

Support the battery tray using a hydraulic bottle jack or other suitable equipment (Fig.5).

FIG 5 SUPPORTED BATTERY TRAY

-

Loosen the three front bolts (Fig.6)

FIG.6 FRONT BATTERY TRAY BOLTS

Writer: mg

SP19-301

Special Bulletin

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Date

Expiration

Release

Page

08.2019

08.2021

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Loosen the three bolts underneath the battery tray (Fig.7).

FIG.7 BATTERY TRAY BOLT (3X UNDERSIDE)

6.

Move the battery tray back approximately 1/4in (7mm) to make room for the reinforcing plate and
shims.

7.

Position the 7770484 reinforcing plate so it covers all 3 hinge holes at the back of the structure
(slide the top right corner between the frame and the battery tray Fig.8).

FIG.8 7770484 PLATE POSITIONNED OVER HOLES

Writer: mg

SP19-301

Special Bulletin

8.

Date

Expiration

Release

Page

08.2019

08.2021

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Mark the center of the lower M6 bolt on the plate using a sharpie (Fig.9).

FIG.9 MARKING THE PLATE WITH A SHARPIE PEN

9.

Remove the plate and drill the marked position using a 1/4in drill bit.

10.

Reposition the drilled plate on the vehicle and secure with one of the supplied bolt/nut (5001815,
502854) (Fig.10).

FIG 10 7770484 PLATE POSITIONNED FOR DRILLING

Writer: mg

SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

1

9(19)

11.

Drill the two remaining holes using a 1/4in drill bit.

12.

Install the new stainless steel lower hinge 2810294 making sure that: