+

New York City Transit - New York

L843

8135

8153

L82J5F4501197

L82J9F4501221

19

+

New York City Transit - New York

L843

8214

8230

L82J9F4501171

L82J1F4501195

17

+

New York City Transit - New York

L843

8270

8293

L82J0F4501222

L82J7F4501251

24

+

New York City Transit - New York

L843

8333

8347

L82J9F4501252

L82J1G9775016

15

+

New York City Transit - New York

L843

8374

8380

L82J3G9775017

L82J9G9775023

7

+

New York City Transit - New York

L844

8381

8170

L82J0G9775024

L82J0G9775105

82

+

New York City Transit - New York

L845

8171

8480

L82J2G9775106

L82J6G9775187

82

PAGE 2 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

PROCEDURE
WARNING

Follow your internal safety procedures. Before performing any welding operation on the vehicle, sensitive
electronic components must be disconnected. Ask a qualified electrician to place the main battery
cut-off switch in the off position and disconnect the affected components per maintenance manual
section 01: Structure.

Figure 1 - Possible Crack Location

PAGE 3 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

NOTE

Retain hardware removed during the procedure for later reinstallation.
1.1.

Remove the access panel above the first curbside window. See Figure 2.

Access Panel
Baselight

Emergency
Valve

Side Sign

Upper Handrail

Door Capping

Wall Handrails

Front Door Rear
Panel

Figure 2 - Parts Identification

PAGE 4 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

1.2.

Remove the front door, rear panel only.

1.3.

Remove the upper handrail and wall hand rails.

1.4.

Mark the height position of the door second capping for later reinstallation. Remove door capping (2 pieces).

1.5.

Remove the door operator connecting rod on top of the door shaft.

1.6.

To remove the door shaft, remove the three bolts under the operator support plate. See Figure 3.

Figure 3 - Remove Door Shaft

1.7.

Remove the emergency valve capping.

1.8.

Disconnect the two chime cord wires and remove chime cord assembly. See Figure 4.

Figure 4 - Remove Chime Cord Assembly
PAGE 5 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

1.9.

Purge the air system, then disconnect the two pneumatic hoses and the connector at the emergency valve.

1.10.

Remove the emergency valve assembly.

1.11.

Disconnect the harness and remove the side sign with the help of an assistant.

1.12.

Remove the window frame screws from the upper horizontal and the front vertical frame portions in order to
facilitate the baselight and melamine removal.

1.13.

To remove the first baselight, start by drilling out the two rivets at the joint of the second baselight. See Figure 5.

Rivet
Locations
Upper Horizontal
Window Frame
Screws

Front Vertical
Window Frame
Screws
Melamine

Figure 5 - Drill Out the Two Rivets and Remove Window Frame Screws

1.14.

Disconnect the harness and remove the baselight.

1.15.

Remove the melamine using a utility knife to cut the double face tape between the wall and the melamine.
The melamine will be reinstalled after the repair, be careful not to damage it. See Figure 6.

Melamine

Figure 6 - Remove Melamine
PAGE 6 OF 13

SERVICE BULLETIN
1.16.

SAV.1E.2012MA

BS3667ER2

Remove the wires and the pneumatic hoses from the wall structure, including the pneumatic drain hose into
the vertical tube (see Figure 7) and attach them temporarily away from the area to be reworked. Remove
and keep the u-channel edge protector.

Drain Hose

Rework Area

Original
Stiffener Plate

Figure 7 - Secure All Hoses and Wires Away From the Rework Area

1.17.

Inspect the area shown in Figure 1. If a crack is found, make 1/8 in. stop holes at one or both ends if possible.

NOTE

All components and surfaces must be protected from cutting or grinding during the repair process.

1.18.

With a cut-off wheel, remove the original stiffener plate between the two vertical tubes, see Figure 7. This
plate will be replaced by N71120, see Figure 8.

PAGE 7 OF 13

SERVICE BULLETIN
1.19.

SAV.1E.2012MA

BS3667ER2

Surface preparation is very important. Grind as required to get smooth flat surfaces without wobbles. Remove
existing welding spatters. The area to prepare has to be approximately 2 in. wider than the area covered by
the new stiffening plates. See shaded areas in Figure 8 for preparation areas to be covered.

N71119

N71120

N71118

Figure 8 - Surface Preparation Area

1.20.

If there is a ground stud in the area, cut it. See Figure 9.

Figure 9 - Cut the Stud
PAGE 8 OF 13

SERVICE BULLETIN
1.21.

SAV.1E.2012MA

BS3667ER2

If there are existing protruding bumps greater than 1/16 in. from the existing weld beads, grind them flush
with the weld bead. The weld on the existing structure should not be more than 1/2 inch, if it is, it should be
ground down to ensure that the maximum of 1/2 inch is respected. The minimum weld size to respect shall
remain equivalent to the thickness of the plate being welded and respecting a maximum weld size of a 1/4
inch. See Figures 10 and 11

Figure 10 - Examples of Weld Beads that May Need to be Ground (Not Limited to These)

1/16 in. or more

Figure 11 - Grind Protruding Bumps of More Than 1/16 in.

PAGE 9 OF 13

SERVICE BULLETIN
1.22.

SAV.1E.2012MA

BS3667ER2

Verify the plates position prior to welding. See Figure 12. It may be required to grind or modify the parts.

Wall
Wall
Flush with the tubes

2 3/8''

Structure

Structure
N71119 is Centered on the Tube

Figure 12 - Plates position

1.23.

A 1/8 in. gap is required between N71119 and the existing weld on the structure, grind if necessary. Press fit
is not acceptable. See Figures 10 and 13.

Figure 13 - 1/8 in. Gap Required on Each Side of N71119
PAGE 10 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

CAUTION

All components must be protected from heat, spatter and flames during the welding process. Refer to
maintenance manual section 01: Structure for welding procedure. Given the heat transfer to the wall, take
care not to damage the parts in the surrounding area, such as the outside fiberglass panel.
1.24.

Plate N71119 must be centered with the vertical tube. N71118 and N71120 must be flush with the inside
face of the tubes. Make a full weld on every edge, represented by the dashed lines in Figure 14. Weld to the
structure tubes only, not to the wall.

Spot type weld, continuous bead, vertical up direction
1/4 in. weld (see the dashed lines)
Welding Process : GMAW
Wire

: 309LSI .045
Gas

: 98% Argon and 2% Oxygen
Welding Parameter : 23V, 350 IPM
Structure Tube
: 1 1/2 in. x 3 in. 12 GA SST
Wall : 14 gauge SST sheet

Structure Tubing

Wall

N71120
Flush With the
Tube Inside Face

N71118
Flush With the
Tube Inside Face
N71119

Structure Tubing

Figure 14 - Weld the Parts in Place

1.25.

Fill the corner gap between the structure and N71118. See Figure 15.

Figure 15 - Fill the Gap for N71118
PAGE 11 OF 13

SERVICE BULLETIN
1.26.

SAV.1E.2012MA

BS3667ER2

Make tack welds on the head of bolt N24104 to replace the previously cut ground stud. See Figures 16 and
17. The position shall be approximately 1 in. above the plate N71119 and centered on the tube. The tack
welds should be on alternate corners of head bolt. This gives a total of 3 tack welds. During the tack weld
operation the dimension from opposite corners should not be reduced by more than 20%.

1 in.

Centered on the Tube

Figure 16 - New Ground Location

1.27.

If the tack welds are higher than the head of the bolt, grind them flush to allow for a proper ground contact.
See Figure 17.

Tack Welds
The Weld Must be
Lower or Flush to the
Head of the Bolt

Figure 17 - Tack Weld the Bolt

PAGE 12 OF 13

SERVICE BULLETIN

SAV.1E.2012MA

BS3667ER2

1.28.

Install the door shaft and apply a torque of 4.4 lb-ft to the three bolts. Use thread locker 9985283 or equivalent
and anti-tamper seal. See Figure 18.

1.29.

Install the door mechanism rod to the top of the shaft, torque to 13.3 lb-ft and apply thread locker 9985283
or equivalent and anti-tamper seal. We recommend applying grease N24412 or equivalent to the pivot, if
needed. See Figure 9.
13.3 lb-ft

Grease

4.4 lb-ft

Figure 18 - Torque Door Shaft

1.30.

Check that there is enough space between the new plate N71119 and the door mechanism. Grind the plate
if necessary.

1.31.

Put the drain hose back in place in the vertical tube and the wires on the structure like they were before.

1.32.

Install the original U-channel edge protector on plate N71120.

1.33.

Install the melamine and route the chime wires through the hole.

1.34.

Install the door shaft capping at its original height.

1.35.

Install the baselight and two new N30702 rivets. Connect the baselight harness.

1.36.

Install the window frame screws.

1.37.

With an assistant, connect and install the side sign. Torque the six bolts to 6.3 lb-ft.

1.38.

Install the emergency handle assembly. Connect the hoses and harness.

1.39.

Install the chime cord assembly. Connect the two wires.

1.40.

Install the emergency handle capping.

1.41.

Install the wall and upper hand rails.

1.42.

Install the access panel.

1.43.

Ask a qualified electrician to connect the components that were disconnected as per maintenance manual
section 01: Structure. Place the main battery cut-off switch in the ON position.

1.44.

Prior to returning the vehicle to service, validate the proper functioning of:
1.44.1. The door.
1.44.2. Chime cord.
1.44.3. Destination sign.
1.44.4. The baselight.
1.44.5. The emergency valve.


PAGE 13 OF 13