INSTRUCTION TO SERVICE
ITS: 58848
SECTION:

526 – Seats & Stanchions

WRITTEN BY:

Scott Geier

SUBJECT:

R & R Driver’s Barrier Upper Door Frame Assembly

ITS-58848

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.

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This procedure outlines the sequences to remove and
replace the 545971 Upper Door Frame on New Flyer buses.
A complete list of the tools and parts required are at the end
of this presentation.
Recommended PPE are cut resistant gloves, safety
glasses, shoes, high visibility work vest and lower back
support brace.
Observe and make note of any other issues related to door
structure and operation.
Follow all safety signs while walking around bus depots.

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D

MAJOR PART NOMENCLATURE

E

A

A - LOWER SUPPORT BRACKET
B – 501245 COLLAR

C - 12mm INLINE BALLJOINT
D - TOP PIVOT TUBE
E – TOP FRAME AND BARRIER GLASS

B

C
Rendered model appearance not indicative of actual parts.
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Sequence 1: Sleeve Set Screw Removal

Process:
Remove the self tapping screw with the
appropriate tool.
Potential Problem(s):
If the head of the screw is stripped or the
screw is seized, use a cold chisel or pliers to remove.
Solution:
When ready to reinstall the ball joint sleeve
use a 5/32” bit to drill out screw. Install
a new or equivalent self tapping screw (NF PN: 36S00012).

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Sequence 2: Loosen Ball Joint
Process:
With the ball joint tube-cover raised and out
of the way, partially loosen the ball joint from the
mounting bracket using a ¾” (19mm) or equivalent wrench.
One to one and a half revolutions should suffice.
Potential Problem(s):
Observe the door mount flange for any looseness.
Tighten as required.

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Sequence 3: Barrier Glass Removal
Process:
Remove the 3/16” and 5/32” allen head bolts
with the appropriate impact socket and
ratchet. Remove the mounting brackets and
set aside. Remove the glass from the frame
and set aside. The glass may be stuck in the
frame, use care to pry it out from the frame.
Potential Problem(s):
Care must be taken to not drop the
glass out of the frame during disassembly.

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Sequence 4: Upper Flange Removal
Process:
Remove the allen head bolts with a ratchet and
place in a recycle bin.
Potential Problem(s):
Care must be taken to not strip out the head of
the screw.
Solution:
If the head of the screw is stripped this can be remedied after door
removal, with the use of pliers.

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Sequence 5: Remove Door
Process:
Once the previously loosened ball joint is removed
From the support bracket, remove the top pivot tube from
the ceiling flange. Again, have a partner support the door
assembly during this operation.

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Sequence 6: Set door aside and support.
Process:
The door assembly can be moved to a stable area on the floor
of the bus for top frame removal. Remove the upper door
flange and bushings for recycling.
The main barrier tube can be properly lubricated at this time
for future reassembly.
Remove upper door frame and transport to a workstation
along with glass and hardware for upper door reconstruction.

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Sequence 7: Rebuild upper door with new upper frame.
Process:
Reinstall safety shield on to the new upper door frame. Secure the safety shield using
the existing 3/16” and 5/32” allen head bolts hardware. Apply 1-2 drops of Loctite (NF
PN: 081034) on the thread and torque hardware to 80-88 in-lbs.
Install the new Delrin bushing (NF PN: 698035) to the upper and lower tube assembly.

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Sequence 8: Replace Upper Door Assembly
Process:
Slide new assembled upper door onto existing lower frame. Insure proper Delrin bushing
fit and install split ring collar (NF PN: 701428), leave collar loose.

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Sequence 9: Re-attach barrier door.
Process:
Install the rebuilt door. Installation is the reverse of
disassembly.
• Install main tube into upper ceiling mount. Insure
the screws are tight on the cup mount to ceiling
location.
NOTE: Upper and lower door assembly mounting
hardware should be torque per installation drawing.

•

Tighten split ring collar as required.

•

Apply Loctite (NF PN: 081034) to the first few
threads of the main bj bolt.

•

Align ball joint, and reinstall with washers. Install
main bj bolt and tighten to 5 ft-lb. of torque.

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Sequence 10: Adjust latches ensure smooth operation.
Process:
Swing upper door into the closed position behind the
driver’s seat, adjust the door tab up or down as required.
Swing entire door into the latched driver’s position, adjust
the door as required.

Open the upper door assembly and replace the latch cover.

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Sequence 14: Final inspection and clean up.
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Perform a final inspection of the door latching mechanism.
Verify door swings open and closes accordingly.
Ensure all surfaces are wiped clean.
Verify all fasteners are in place and tightened accordingly.
Remove all tools, trash and old parts from bus.

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Tool List
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Cordless Wrench
8.0V Batteries and Chargers
Philips #2 Screw Driver
¾” or equivalent 19 mm wrench
3/16” and 5/32” Allen wrench and bits
Vise grip pliers
Pry Bar (Optional)
Chisel (Optional)
Cordless Drill
5/16” Drill Bit
7/16” Drill Bits
Screw Extractor (Optional)
3/8 – 16 Tap (Optional)
Isopropyl Alcohol (Optional)
Rags / Towels

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3/8 – 16 Tap (Optional)
Isopropyl Alcohol (Optional)
Rags / Towels
3/8” Drive Torque Wrench – 4 to 20 ft.-lb. Range
Socket Adapter. 3/8 Female Sq, ½: Square
Torque Seal Indicator Paste.

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