INSTRUCTION TO SERVICE
ITS: 58950
SECTION:

246

AIR, BRAKE & LEVELLING SYSTEM.

WRITTEN BY:

Michael Rooney

SUBJECT:

Remove and replace front air springs.

ITS58950
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
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.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Drain the air from the air system.
3. Raise coach in accordance with the New Flyer Service Manual using wheel lifts and support chassis with jack
stands.
4. Using the wheel lifts, lower the front suspension so that there is 3” (76 mm) of clearance between the top of the
axle and the front axle bump stops.
5. Disconnect the air-line at the top of the air spring.
6. Remove the lower nut attaching the air spring to the lower mounting plate. Set the hardware aside for reuse.
7. Remove the nuts and washers securing the top of the air spring to the chassis. Set the hardware aside for
reuse.
8. Slide the air spring out of the chassis.
9. On the work bench, remove the 90 deg elbow fitting and air line connector from the air spring. Note the
installation direction of the fitting.
10. Check the label on the new air spring NF P/N 303734 to ensure it is the latest revision.
a.

The label on the top of the air spring should have a #4 at the top. The date code at the bottom right of the
label should read 20-080 or higher. Figure 1.

Date Code:
20 = Year 2020
015 = 15th day of year.

Figure 1: Air Spring Label.
11. Install the 90 deg elbow fitting and air line connector previously removed from the old air spring on the new
replacement air spring. Install the fitting finger tight using Loctite 567 NF P/N 8110442 on the threads then
apply 1 – 1.5 turns past finger tight and align the fitting with the installation orientation previously noted.
12. Align the stud in the bottom of the air spring with the hole in the lower mounting plate. Install the mounting
hardware removed earlier.
13. Align the studs on the top of the air spring with their respective mounting holes and install the mounting
hardware removed previously.

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14. Torque the upper and lower mounting hardware to spec:
a.

Torque the lower spring to mounting plate hardware to 20 FT-LBS using Never Seize NF P/N 5928660
on the threads.

b.

Torque the upper ¾” UNC hardware to 45 FT-LBS using Never Seize NF P/N 5928660 on the threads.

c.

Torque the upper ½” UNC hardware to 20 FT-LBS using Never Seize NF P/N 5928660 on the threads.

15. Reconnect the ½” air line to the air spring.
a.

Install the air line connector nut finger tight then apply 4 turns past finger tight.

Figure 2: Air Spring Installation (street side)
16. Repeat steps 5 – 15 to replace the air spring on the other side of the bus.
17. Lower bus in accordance with the New Flyer Service Manual.
18. Turn the main battery disconnect switch to the “ON” position.
19. Start the bus and allow the air system to build up air pressure.
20. Check for leaks at the air spring air line connections and repair as necessary.
21. Remove all tools and debris and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Remove and replace front air springs.

People

Hours

Labor Time

1

1.5

1.5

PARTS REQUIRED
Item

Part Number

1

303734

BELLOWS AIR SPRING 1T15L-4

Qty.
per
Coach
2

2

5928660

NEVER SEIZE

0.010

EA

3

8110442

LOCTITE 567 THREAD SEALANT

0.010

EA

Description

Units

Notes

EA

SPECIAL TOOLS REQUIRED
Item
1

Part Number

Description

Qty.
per
Coach

Units

Notes

NO SPECIAL TOOLS REQUIRED

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