INSTRUCTION TO SERVICE
ITS: 58734
SECTION:

420 – Exterior Doors

WRITTEN BY:

Daniel Tice

SUBJECT:

Door Louver Stiffener Rework

ITS-58734

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.

SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY
STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.
Issue: Corner pillar access door louver breaking at joint.
Solution: Install corner pillar door louver joint stiffener.

PROCEDURE:

Removal of the corner pillar access door.
1) Park bus on a flat surface and apply the parking brake.
2) Turn the main battery disconnect switch to the “OFF” position.

Wiring located inside
Corner Pillar Access Doors.

Curb Side
Corner Pillar
Access

Curb Side
Corner Pillar
Access

Figure 1: Corner Pillar Access Door Reference.

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3) Inspect the doors for damaged and cracked louvers.
4) If broken or cracked louvers are found open the corner pillar access door and disconnect wiring.
5) Remove corner pillar access door (Illustration is for reference only) See figure 2.
a. Remove nylon lock nut #1 (NF PN: 261556).
b. Remove flat washer #2 (NF PN: 50W04000).
c.



Remove the door from bus and place on clean smooth protected surface not to damage the paint.
NOTE: Discard nylon lock nuts (# 1 NF PN: 261556.)

1,2

1,2

Figure 2: Removal of Corner Pillar Access Door Reference.

1

261556

2

50W04000

Nut, Hex Lock Steel 1/4”- 20

Washer, Flat 1/4”- SST

8
8

EA
EA

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WARNING: PPE required.
 NOTE: Wear safety glasses and gloves while cleaning and preparing surfaces. Face shield and
dust mask are required while grinding.
6) Prepare door panel for the louver stiffener bracket.
a. Fold Insulation back out of work area as needed. See figure 3.
b. Clean the area where the stiffener brackets will be installed. See figure 3.
c. Once these areas are clean, scuff with 200 grit sandpaper using hand pressure.
d. Once area is abraded clean entire bond surface with isopropyl alcohol and clean lint free cloth.
7) Prepare door louver stiffener bracket. See figure 3.
a. Clean entire bond surface area of the stiffener bracket #3 (NF PN: 811052) with isopropyl alcohol and
clean with lint free cloth.

Hinge plate removed
for clarity.

Steps 7A-D

3

Fold insulation back
out of work area as
needed.

Step 8A

Figure 3: Louver Door Stiffener Bracket Preparation Location Reference.

3

811052

Bracket, Louver Support

2

EA

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8) Install louver stiffener bracket using steps 8 A-F.
WARNING: PPE required.
** SAFETY: Applicator shall use rubber gloves and approved respirator when using Primer and
Adhesive.
a. Wipe down all contact surfaces with clean lint free cloth, ensure that surface area is free of grease
and debris. See figure 4.
b. Create a temporary splint to address any misalignment and mask off outer surface of the cracked
region. Ensure the masking takes form to the contour of the louver and door to prevent adhesive from
squeezing through.
c.

Apply Plexus PC120 Primer #4 (NF PN: 067196) on the surfaces of the stiffener bracket using a
clean cloth. Remove excess primer with clean lint free cloth and allow to flash for a minimum of 1
minute and a maxim of 3 minutes.

d. Apply Plexus MA920 Adhesive #5 (NF PN: 067197) to indicated surface. See figure 4.
 NOTE: When using a new nozzle dispense adhesive the length of the nozzle before
applying to primed surface. Within 4 minutes of applying the plexus adhesive assemble the
stiffener bracket item #3 (NF PN: 811052) to the panel. See figure 4.
e. Place bonding surfaces together, press with 1 PSI of pressure with weights or clamps and allow 20
minutes of cure time before removing.
f.

After curing remove any excess material that squeezed-out.

A-E
3,4,5

Figure 4: Louver Door Stiffener Bracket Preparation Location reference.
3

575286

Bracket, Corner Door Hinge SST

4

067196

5

067197

2

EA

Primer, PC120

0.10

AR

Plexus MA 920

0.10

AR

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10) Remove splint and have the exterior of the door painted.
11) Paint the interior of door with New Flyer standard white paint #6 (NF PN: 375246). See figure 5.

6

Figure 5: Louver Door Stiffener Bracket Paint Location reference.

Item

Part Number

6

375246

Part Description

White Paint

Qty.
per
Coach
0.10

Units

EA

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12) Re-install corner pillar access door (Illustration is for reference only) See figure 6.
a. Install flat washer #2 (NF PN: 50W04000).
b. Install nylon lock nut #1 (NF PN: 261556).



NOTE: Do not tighten hardware completely until door has been aligned correctly. See figure 7.

1,2

Hinge
Plates
1,2

Figure 6: Installation of Corner Pillar Access Door Hardware Location Reference.

1

261556

2

50W04000

Nut, Hex Lock Steel 1/4”- 20

Washer, Flat 1/4”- SST

8
8

EA
EA

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13) Align Bottom of door panel to be flus with rear door .26” +/- .06. See Figure 7
14) Open and close the door gently to ensure it is aligned correctly with no binding and functions as it should,
adjust as needed then tighten hardware #2 (NF PN: 261556) See figure 6.
15) Re-install lights in door panel.
16) Re-connect and secure wiring to the door panel.
17) Close and lock access door when work is complete.
18) Turn the main battery disconnect switch to the “ON” position.

Door Panel to be
flush with rear door
.26” +/- .06.

Figure 7: Adjustment of Corner Pillar Access Door Location Reference.

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LABOUR ESTIMATE
Operation
1

Door Louver Stiffener Rework

Men

Hours

1

1.5

Labor Time
M X HR
1.5

Total Man hrs. 1.5 hrs.

PARTS REQUIRED FOR DOOR HINGE PLATE AND LOUVER SUPPORT REWORK
Item

Part Number

1

261556

2

50W04000

3

Description
Nut, Hex Lock Steel 1/4”- 20

Qty. per bus

Units

Notes

EA

Washer, Flat 1/4”- SST

8
8

575286

Bracket, Corner Door Hinge SST

2

EA

4

067196

Primer, PC120

.010

EA

5

067197

Plexus MA 920

.010

EA

6

375246

White Paint

0.10

EA

EA

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