NHTSA ID Number: 10173613
Manufacturer Communication Number: FCP 478
TSB/Document Date: 2020-04-08
Summary
This service bulletin advises owners of affected vehicles that ZF has notified MCI
that some brake chambers installed on the ZF drive axle have had water ingress, causing malfunction of the pneumatic brake system and dragging brakes during sub-zero temperatures. The service bulletin advises how owners may have their vehicles repaired.
Subject: ZF Brake Chamber Rework
Field Change Program:
Field Campaign
Coach Section:
04-Brakes & Air system
FCP Number:
Revision:
478
A
P/N:
02-01-1418, 02-01-1420
Date:
03/20/2020
Type:
Product Integrity
Application:
Coach Model
Model Year
VIN
J4500
2020
69515 - 69673
J3500
2019 - 2020
21027 - 21042
D45CRT-LE
2019
81019 - 81033
This field campaign does not necessarily apply to all the above-mentioned coaches.
The owners of the coaches affected by this field campaign will be advised by a letter
indicating the Vehicle Identification Number (VIN) of each applicable coach.
Read this entire procedure before beginning work.
Use Safe Shop Practices at All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and
protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Position the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the engine
compartment.
FCP 478
ZF Brake Chamber Rework
1.0 Description
Customer complaint:
ZF has notified Motor Coach Industries (“MCI”) that some of the brake chambers installed
on the ZF drive axle have had water ingress, causing malfunction of the pneumatic brake
system and dragging brakes during sub-zero temperature.
Cause:
ZF concluded that the new paint and washing process established in ZF’s production line
led to water ingress in the horizontal mounted piston-type brake chamber. During freezing
temperatures the water inside the pneumatic system may freeze, causing dragging
brakes.
Corrective action:
MCI and ZF urge owners of the affected coaches to have the following procedure
performed as soon as possible.
2.0 Material requirements
ITEM
1
2
3
PART NO
6407942
04-01-1250
04-01-1249
QTY
4
1
1
U/M
EA
EA
EA
DESCRIPTION
Nut, Locking M16 X1.5
Brake Cylinder RH
Brake Cylinder LH
3.0 Special tools
No special tools required.
4.0 Procedure
4.1
Removing brake chamber
Apply the coach parking brake.
Page 2 of 9
FCP 478
ZF Brake Chamber Rework
Remove the drive axle wheels by following the instructions on page 15A-9 of the coach
maintenance manual.
Release and cage the brake chamber by rotating the caging bolt counter-clockwise. The
force to compress the spring must not exceed 33 FT-LBS during the caging process.
Cage the brake chamber
by rotating the caging
bolt counter-clockwise
CAUTION
Do not use impact tools to cage the brake chamber
Release the parking brake.
Drain air from all tanks.
Page 3 of 9
FCP 478
ZF Brake Chamber Rework
Locate the curbside and driver side brake chamber air lines on the drive axle.
Curbside brake
chamber
Disconnect air lines on ports 11 and 12 of the curbside and driver side brake chambers.
Visually mark the installation position of the brake chambers and air to assist during
reassembly.
If required, clean the general area around the brake chambers to prevent debris from
falling into the brake caliper openings during later steps.
Remove and discard mounting nuts from each brake chamber.
Remove and discard
mounting nuts
Remove brake chambers from both curbside and driver side wheel caliper housings.
Clean the mating surfaces of both the removed brake chambers and calipers.
Additionally, insert a clean, suitably sized plug into the brake cylinder bore on the brake
calipers.
Motor Coach Industries Ltd.
Page 4 of 9
FCP 478
ZF Brake Chamber Rework
4.2
Installing new brake chamber
Clean the new brake chambers and caliper mounting surfaces and then remove plugs in
brake cylinder bores.
CAUTION
Cover brake chamber opening on the brake caliper when cleaning the mounting
surfaces so as to prevent the entry of any contaminants.
Do not use grease containing molybdenum sulfide on the brake caliper spherical
cup or brake chamber sealing surface. Always use the recommended white
lithium-based grease.
Using the previously made markups position the RH brake chamber, MCI P/N: 04-011250, on the curbside and LH brake chamber, MCI P/N: 14-01-1249, on the driver side.
Position the RH
brake chamber, MCI
P/N: 04-01-1250
NOTE: Replacement brake chambers should come from ZF with a yellow sticker. Verify
that the sticker is present before installation.
Yellow sticker on the
brake chamber
Page 5 of 9
FCP 478
ZF Brake Chamber Rework
CAUTION
Do not attempt to loosen the clamp band bolt in order to rotate and reposition the
air inlet ports. Do not use clamping tools such as vise grips to hold the pushrod.
The spring brake actuator contains an internal boot to seal the caliper from
containments and may be damaged if brake chamber is rotated or if clamping tools
are used on the pushrod.
Ensure the brake chamber is properly positioned so that the breather tube is not
facing directly downward toward the road surface.
Secure brake chamber to wheel caliper housing using new mounting nuts, MCI P/N
6407942. Using a flexible head torque wrench (24mm socket), apply an initial torque of
25 FT-LBS and a final torque of 143 FT-LBS.
Using a flexible head
torque wrench secure
the brake chambers
Uncage the brake chambers by tightening the caging bolts (clockwise) to a torque of 14.75
FT-LBS. Do not exceed 52 FT-LBS.
Reconnect air lines to both curbside and driver side brake chambers.
Turn the main battery disconnect switch to the “on” position.
Start vehicle and charge air system to normal operating pressure. Inspect for air leaks.
Release the parking brake and actuate service/parking brakes several times and check
for air leaks.
Install the drive axle wheels as specified on Page 15A-9 of the MCI maintenance manual.
Tag the removed brake chambers and release the cage spring by rotating the bolt
clockwise.
Page 6 of 9
FCP 478
ZF Brake Chamber Rework
5.0 Field Change Program Conditions:
The parts required for this change will be supplied without charge.
A labor allowance of 6.4 hours will be granted for the rework.
This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt
of the attached “MCI Field Change Program Verification Form” and a “Warranty Claim
Form” as detailed in your Owner Warranty manual to MCI’s Warranty department. A “MCI
Field Change Program Verification Form” needs to be submitted for each VIN affected.
Photocopy the attached “MCI Field Change Program Verification Form” as required for
the number of affected coaches in your fleet.
This program will end on Mar 20, 2021.
Motor Coach apologizes for any inconvenience resulting from this campaign but urges
you to implement this change as soon as possible.
Sincerely,
Motor Coach Industries
Page 7 of 9
FCP 478
ZF Brake Chamber Rework
5.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT)
FCP INFORMATION – ONE FORM PER UNIT
FCP#: _________
Coach Model ___________
COACH SERIAL #:
Model Year _______________
DATE COMPLETED __ / __ /____
(At least the last 5 digits)
MILEAGE:
IMPORTANT: TO RECEIVE CREDIT FOR ANY ALLOWABLE LABOR CHARGES, THIS
VERIFICATION FORM MUST BE RETURNED TO MCI UPON COMPLETION OF THE
FCP.
SUBMITTED BY: (Please Print)
______________________________________________________
DATE
__ / __ /____
TITLE: (Please Print) _____________________________________________
SIGNATURE:
________________________________________________________________
COMMENTS:
Page 8 of 9
FCP 478
ZF Brake Chamber Rework
FAX TO: 800-360-8886
Mail or fax the completed limited warranty claim form and verification form to MCI’s
warranty department, or photocopy and mail to:
MCI Fleet Support
Attn: Warranty Department
7001 Universal Coach Drive Louisville, KY 40258
Fax Number 1-800-360-8886
To receive credit for the hours used to complete this task. Contact the MCI Fleet Support
Technical Center at 1-800-241-2947 for any further information.
Page 9 of 9
- Mixes well with conventional fluids
- Low-moisture formula provides excellent vapor lock...
- Ideal for hydraulic and disc brakes
- Provides an extra margin of safety in extreme braking...
- Mix of polyglycol ethers ensures hot brake-system operation...
- Excellent for ABS, disc and drum brake systems
- Delivers braking power when needed by avoiding a spongy...
- Both wet and dry boiling points exceed the minimum...
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TSB/Document ID: FCP 478
Replacement Service Bulletin Number:
MFR Communication Date: 2020-03-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: SERVICE BRAKES, AIR
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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