INSTRUCTION TO SERVICE
ITS: 58910
SECTION:

203

FRONT SUSPENSION

WRITTEN BY:

Michael Rooney

SUBJECT:

Retrofitting new shock dust covers, height sensor & harness assembly.
40’ Buses with Smart Rider on Front & Rear axles.

ITS58910
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 and install appropriate jack stands to support
the vehicle.
FRONT SUSPENSION
4. Use wheel lifts on the front suspension to lift the front suspension slightly to support the weight of the front axle
and suspension components.
Caution:

ALWAYS support the weight of the axle when replacing shock absorbers.

5. Disconnect the electrical connector that attaches the shock absorber height sensor to the vehicle harness.
a.

Remove clamps used to attach the harness to the under body and set them aside.
Note: If the harness is bundled and tyrapped around the shock dust cover, the harness
must be rerouted when the shock absorber unit is reinstalled.

6. Remove the four nuts retaining the upper shock mounting plate to the chassis bracket.
7. Remove the protective cap from the lower shock mounting nut and remove the nut.

Height Sensor Harnesses

Height Sensor Connector

Figure 1: Front Shock Absorbers (Looking towards the front of the vehicle).
8. Remove the clamping plate, rubber bushing and centering ring from the shock stud noting the location and
orientation of the parts.
9. Compress the lower shock sufficiently to remove the shock stud from the lower mounting bracket. Remove
the remaining rubber bushing from the shock stud.
10. Remove the shock absorber assembly from the vehicle and disassemble the upper mounting components as
follows:
a.

Remove the protective cap from the upper shock mounting nut and remove the nut.

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b.

Remove the clamping plate, rubber bushing and centering ring from the shock stud noting the location
and orientation of the parts.

c.

Remove the mounting plate, rubber bushing and steel sleeve from the shock stud.

11. Take the shock assembly to the work bench and secure the unit in a vice by the upper shock stud with the
side of the dust cover containing the sensor channel facing upward.



NOTE:

Use soft jaws in the vice to protect the threads on the upper shock stud from damage.

12. Using a rubber mallet, apply a sharp blow to the upper end of the dust cover at the square open end of the
channel in the dust cover. The dust cover should pop loose from the shock absorber.

Figure 2: Rubber Mallet Use To Release Dust Cover
13. Slide the dust cover and sensor harness off the shock absorber body and set aside.
14. Install a new dust cover/sensor/harness assembly NF P/N 6482203 over the shock body.
a.

Align the square section channel with the magnet on the outside of the shock body and slide the dust
cover over the shock body. Center the opening in the top of the dust cover with the grey circular retaining
ring below the bushing on the shock stud.

Figure 3: Install Dust Cover & Center Over Grey Retaining Ring.
b.

Using a rubber mallet, apply a sharp blow to the bottom of the dust cover to seat the cover on the grey
circular retaining ring. Take care not to hit the height sensor connector.

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Figure 4: Using Rubber Mallet To Seat Dust Cover on Retaining Ring.
15. Install the dirt exclusion cover at the top of the dust cover.
Dirt Exclusion Cover

Dirt Exclusion Cover

End of Height Sensor Cavity

Dust Cover

Figure 5: Dirt Exclusion Cover.
16. Assemble the upper shock mounting components as follows:
a.

Slide the steel sleeve and rubber bushing onto the shock stud. Ensure that the flat side of the rubber
bushing seats against the shock body.

b.

Place the mounting plate onto the rubber bushing ensuring that the mounting plate seats on the pilot
diameter of the rubber bushing.

17. Assemble the remaining upper shock mounting components as follows:
a.

Slide the centering ring and rubber bushing onto the shock stud ensuring that the pilot diameter of the
rubber bushing seats within the concave side of the centering ring.

b.

Install the clamping plate onto the rubber bushing ensuring that the concave side of the clamping plate
seats against the flat side of the rubber bushing.

c.

Install the M16 self-locking nut and torque to 56 Ft lbs using NEVER SEEZ NF P/N 5928660.

d.

Install the protective cap over the lock nut.

18. Align the four holes in the upper shock mount plate with the studs on the chassis mounting bracket.
19. Install four lock nuts NF P/N 203772 and torque the lock nuts to 35 Ft lbs using NEVER SEEZ NF P/N 5928660.
20. Assemble the remaining lower shock mounting components as follows:
a.

Slide the rubber bushing onto the shock stud ensuring that the flat side of the rubber bushing seats against
the shock body.

b.

Compress the shock sufficiently to allow the shock stud to enter the lower mounting bracket.

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21. Assemble the remaining lower shock mounting components as follows:
a.

Slide the centering ring and rubber bushing onto the shock stud ensuring that the pilot diameter of the
rubber bushing seats within the concave side of the centering ring.

b.

Install the clamping plate onto the rubber bushing ensuring that the concave side of the clamping plate
seats against the flat side of the rubber bushing.

c.

Clock the dust cover height sensor cavity approx. 30 degrees off the center line of the bus to ensure that
the upper mounting plate nuts are not aligned with the end of the height sensor cavity in order to create
better clearance and prevent contact between the bolt and the cover.

d.

Install the M16 self-locking nut and torque to 56 Ft lbs using NEVER SEEZ NF P/N 5928660. Take care
that the dust cover does not rotate out of position when torqueing the nut.

e.

Install protective cap over the lock nut.

Figure 6A: Street Side Dust Cover Orientation.

Figure 6B: Curb Side Dust Cover Orientation.

22. Connect the height sensor harness to the vehicle harness. Take care to ensure that the screw connector is tight
and secure.

a.

Route the shock sensor harness using the existing harness retaining clips. Bundle the remaining vehicle
harness length and secure with tie wraps NF P/N 5955945.

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Bundle Vehicle Harness Here.

Shock Dust Cover

Harness Connector to Vehicle Harness

Air Spring Bellows
Harness Connector

Figure 7: Curbside Shock Sensor Harness Routing.

Bundle Vehicle Harness Here

Shock Sensor Harness
Air Spring Bellows
Shock Dust Cover

Figure 8: Curbside Shock Sensor Harness Routing.
REAR SUSPENSION
23. Use wheel lifts on the rear suspension to lift the rear suspension slightly to support the weight of the rear axle
and suspension components.
Caution:

ALWAYS support the weight of the axle when replacing shock absorbers.

24. Locate the height sensor harness wires on the rear set of shock absorbers and remove the hardware that
secures the harness wires to the bus. Note the locations of each clip and set them aside for reuse later.
Disconnect each of the harnesses at the connectors where they attach to the main vehicle harness.

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25. Remove the four nuts retaining the upper shock mounting plate to the chassis bracket on each side. Set the
hardware aside for reuse.
Note:

The two inboard mounting bolts that retain the air-line support bracket are slightly longer to
accommodate the thickness of the bracket. Note the location of these bolts for reassembly.

Height Sensor Harness

Shock Dust Covers

Height Sensor Harness Connector

Figure 9: Rear Shock absorbers upper hardware (drive shaft removed for clarity).
26. Remove the protective caps from the lower shock mounting nuts and remove the nuts.
27. Remove the rubber bushings from the shock studs, noting the location and orientation of the parts.
28. Compress the lower shocks sufficiently to remove the shock studs from the lower mounting brackets.
29. Remove the remaining rubber bushings from the shock stud.
30. Remove the shock absorber assemblies from the vehicle.

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Lower Shock Mounts

Figure 10: Rear Shock absorbers lower hardware (drive shaft removed for clarity).
31. Take the shock absorbers to the work bench. Procedure for removal and replacement of the dust covers on
the rear shocks is the same as for the front shocks. See Steps #10 to #15 for the R&R procedure.
32. Assemble the upper shock mounting components as follows:
a.

Slide the rubber bushing onto the shock stud. Ensure that the flat side of the rubber bushing seats
against the dirt excluder.

b.

Place the mounting plate onto the rubber bushing ensuring that the mounting plate seats on the pilot
diameter of the rubber bushing.

33. Assemble the remaining upper shock mounting components as follows:
a.

Slide the rubber bushing onto the shock stud ensuring that the pilot diameter of the rubber bushing seats
on the mounting plate.

b.

Install the clamping plate onto the rubber bushing ensuring that the concave side of the clamping plate
seats against the flat side of the rubber bushing. Install the M16 self-locking nut and torque to 56 Ft –
Lbs using Never Seize NF P/N 5928660 on the threads.

c.

Install the protective cap over the lock nut.

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Figure 11: Rear Shock absorbers Upper hardware detail.
34. Align the four holes in the upper shock mount plate with the welded nuts on the chassis mounting bracket.
35. Position the air line support bracket over the two holes on the inboard side of the mount plate.
36. Install the four bolts and washers and torque to 23 Ft Lbs using Never Seize NF P/N 5928660 on the threads.
Note:

The two inboard mounting bolts that retain the air-line support bracket are slightly longer
to accommodate the thickness of the bracket. Ensure that the two longer bolts are
installed at the bracket location.

37. Assemble the lower shock mounting components as follows:
a.

Slide the rubber bushing and shock mount plate onto the shock stud ensuring that the flat side of the
rubber bushing seats against the shock body.

b.

Compress the shock sufficiently to allow the shock stud to enter the lower mounting bracket.

38. Assemble the remaining lower shock mounting components as follows:
a.

Slide the centering ring and rubber bushing onto the shock stud ensuring that the pilot diameter of the
rubber bushing seats within the concave side of the centering ring.

b.

Install the clamping plate onto the rubber bushing ensuring that the concave side of the clamping plate
seats against the flat side of the rubber bushing.

c.

Clock the dust covers on the shock absorbers so that the molded plug on the sensor harness faces the
rear of the vehicle as seen in Figure 9.

d.

Install the M16 self-locking nut and torque to 56 Ft -Lbs using Never Seize NF P/N 5928660 on the
threads. Ensure that the dust cover does not rotate when the M16 nut is torqued.

e.

Install the protective cap over the lock nut.

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Figure 12: Rear Shock absorbers Lower hardware detail.
39. Route the height sensor harnesses forward and connect them to the vehicle wiring harness. Take care to ensure
that the screw connector is tight and secure.
40. Secure the height sensor harnesses to the vehicle chassis using the original hardware.
41. Lower the bus in accordance with the New Flyer Service Manual.
42. Turn the main battery disconnect switch to the “ON” position.
43. Ensure that the latest version 21 Smart Rider software is loaded in the bus. The software is available from your
regional product support manager (RPSM).
44. Perform a ride height sensor calibration. Refer to Section 8 of the Service Manual for the calibration procedure.
45. Road test the bus to ensure proper operation
46. Remove all tools and debris and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Retrofitting new shock dust covers, height sensor & harness

People

Hours

Labor Time

1

3.0

3.0

assembly.

PARTS REQUIRED
Item

Part Number

Description

1

6482203

SENSOR ASSY-RIDE HEIGHT

2

5955945

TYRAP – 14.0 BLACK

3

5928660

NEVER SEIZE

Qty.
per
Coach
4

Units

9

EA

0.03

EA

Notes

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

Description

Qty.
per
Coach

Units

Notes

No Special Tools Required

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