-

Mounting surfaces are cleaned from old undercoating using emery cloth or sandpaper
(expose primed frame surfaces – not bare metal).

-

New plastic bushing 284607 and washer 502723 are installed at the pivot point (Fig.11).

-

Door is fully supported by the top hinge, not the lift table (no gap at the top pivot point)
(Fig.12).

-

New M6 bolts, nuts, locks & washers (5001815, 502854, 502570 & 430406) are used to
secure the lower hinge at the vehicle structure point (Fig.13).

-

The stainless reinforcing plate (7770484) is installed at the backside of the frame (plate
must be installed between the frame and the battery tray floor (Fig.15)).

-

Door is adjusted properly. There should be an even (parallel) gap of at least 0.080” (2mm)
at the top of the door and a 0.177”+/- 0.060” (4.5 +/-1.5 mm) gap between the door and the
vehicle rear fender (see step 17 below for final adjustment details).

-

All bolts are torqued to 84 lb-in (apply blue Loctite 243 or equivalent medium strength
thread locker on all fastener threads & apply a stripe of tamper proof indicator paint (torque
seal) to the bolt heads (Fig.14)).

FIG.11 WASHER & BUSHING POSITION

Writer: mg

FIG.12 UPPER SUPPORT- NO GAP ALLOWED

SP19-301

Special Bulletin

FIG.13 LOWER HINGE COMPONENTS

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FIG. 14 TIGHTENING TORQUE

FIG.15 REINFORCMENT PLATE INSTALLED

13.

Remove the battery tray bolt one by one to apply blue Loctite 243 or equivalent medium strength
thread locker to the threads (do all 6 bolts).

14.

Tighten the screw halfway.

15.

Insert a 030082 shim between the tray and the frame at all bolt location and tighten the bolts (Fig.16
& Fig.17).

FIG.16 SHIMS POSITION
Writer: mg

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FIG.17 INSTALLED 030082 SHIM

16.

Re-Torque the 6 bolts to 47 lb-ft & apply a stripe of tamper proof indicator paint (torque seal) to
the bolt heads.

17.

Remove door support installed at step 2 and open and close the door several times to make sure it
is working properly, check door top and side adjustments. There should be an even (parallel) gap of
at least 0.080” (2mm) at the top of the door and a 0.177”+/- 0.060” (4.5 +/-1.5 mm) gap between the
door and the vehicle rear fender (Fig.18).

FIG.18 COMPRESSOR DOOR HORIZONTAL & VERTICAL GAPS
Writer: mg

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NOTE
If gap is out of spec the compressor door may be adjusted for proper fit by untightening hinge bolts:

- Loosen the bolts holding the hinges to the vehicle structure to shift the door
horizontally LEFT or RIGHT.
- Loosen the bolts holding the hinges to the door frame to shift the door vertically UP or
DOWN.
- If upper hinges must be readjusted, re-torque the upper fasteners to 68lb-in

18.

Make sure that there is a stripe of tamper proof indicator paint (torque seal) on all hinges bolt
heads.

PART 2: RADIATOR DOOR LOWER HINGE REPLACEMENT

1. Fully open the vehicle radiator door (rear, road side of vehicle Fig.19).

FIG.19 VEHICLE RADIATOR DOOR

Writer: mg

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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.20).

FIG.20 SUPPORTING THE DOOR

3. Remove the door support arm (unscrew from vehicle structure side) fully open the door and move
the arm out of the way (Fig.21).

FIG.21 DOOR SUPPORT ARM

Writer: mg

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4. Unscrew, remove & discard the vehicle structure part of the radiator door lower hinge (2X M6
bolts Fig.22)

FIG.22 HINGE PART TO BE REMOVED (RADIATOR DOOR)

5. Drill-out the two welded nuts using a 3/8in drill bit (Fig.23 & Fig.25).
6. Remove the remaining part of the welded nuts (backside of frame) using a sharp flat chisel and
hammer (Fig.24).

FIG.23 DRILLING THE WELDED NUTS

Writer: mg

FIG.24 WELDED NUTS REMOVAL WITH CHISEL

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FIG.25 DETAIL OF DRILLED HOLE

7. Position the 7770478 reinforcing plate so it covers both holes at the back of the structure (Fig.26).

FIG.26 7770478 PLATE POSITIONNED OVER HOLES

8. Mark the center of one of the holes on the plate using a sharpie (Fig.27).

FIG.27 MARKING THE PLATE WITH A SHARPIE PEN
Writer: mg

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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) as shown in Fig.28.

FIG.28 7770478 PLATE POSITIONNED FOR DRILLING

11. Drill the remaining hole using a 1/4in drill bit.
12. Install the new stainless steel lower hinge 2810296 making sure that:

Writer: mg

-

Mounting surfaces are cleaned from old undercoating using emery cloth or sandpaper
(plate must be mounted flat on the primed frame surface – not bare metal).

-

New plastic bushing 284607 and washer 502723 are installed at the pivot point (Fig.29.

-

Door is fully supported by the top hinge, not the lift table (no gap at the top pivot point)
(Fig.30).

-

New M6 bolts, nuts, locks & washers (5001815, 502854, 502570 & 430406) are used to
secure the lower hinge at the vehicle structure point (Fig.29).

-

The stainless reinforcing plate (7770478) is installed at the backside of the frame (Fig.32).

-

Door is adjusted properly. Bottom of the door should fit flush with the bottom of the fender
(+/- 2mm) and there should be a 0.236” (6 mm) gap between the door and the vehicle rear
fender (see step 14 below for final adjustment details).

-

All bolts are torqued to 84 lb-in (apply blue Loctite 243 or equivalent medium strength
thread locker on all fastener threads & apply a stripe of tamper proof indicator paint (torque
seal) to the bolt heads (Fig.31)).

SP19-301

Special Bulletin

FIG.29 LOWER HINGE COMPONENTS

FIG. 31 TIGHTENING TORQUE

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FIG.30 UPPER MOUNT (NO GAP ALLOWED)

FIG.32 REINFORCMENT PLATE INSTALLED

13. Reinstall the door support arm following hardware stacking order in Fig.33 below. Apply medium
strength thread locker (blue Loctite 243 or equivalent) to the bolt threads and tighten just enough
to feel a slight resistance between washers and arm when moving (no specific torque value
applies here, arm movement must remain smooth).

FIG. 33 SUPPORT ARM INSTALLATION
Writer: mg

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Date

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14. Remove door support installed at step 2 and open and close the door several times to make sure
it is working properly, check door bottom and side adjustments. Bottom of the door should fit flush
with the bottom of the fender (+/- 2mm) and there should be a 0.236” (6 mm) gap between the
door and the vehicle rear fender (Fig.34).

FIG.34 RADIATOR DOOR HORIZONTAL & VERTICAL ADJUSTMENT

NOTE
If gap is out of spec the compressor door may be adjusted for proper fit by un-tightening hinge
bolts:
- Loosen the bolts holding the hinge to the vehicle structure to shift the door horizontally
LEFT or RIGHT.
- Loosen the bolts holding the hinge to the door frame to shift the door vertically UP or
DOWN.
- If upper hinges must be readjusted, re-torque the upper fasteners to 68lb-in

Writer: mg

SP19-301

Special Bulletin
Date

Expiration

Release

Page

08.2019

08.2021

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15. Make sure that there is a stripe of tamper proof indicator paint (torque seal) on all hinges bolt
heads.

16. Reset main circuit breakers and set the battery master switch (master cut-out) to the ON position.

PARTS / WASTE DISPOSAL
Return replaced parts to Prevost with A.F.A. for full reimbursement.
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

ESTIMATED TIME
The time required to perform this special bulletin is approximately three (3.0) hours.
OTHER
VBC Bulletin

N/A

Fail Code

18.05

Defect Code

09

Syst. Cond

B

Causal Part

280552

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Prevost engages in a continuous program of testing and evaluating to provide the best possible product. Prevost, however, is not
committed to, or liable for updating existing products.

Writer: mg