27. 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.
28. 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.

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Height Sensor Harness

Shock Dust Covers

Height Sensor Harness Connector

Figure 11: Rear Shock absorbers upper hardware (drive shaft removed for clarity).
29. Remove the protective caps from the lower shock mounting nuts and remove the nuts.
30. Remove the rubber bushings from the shock studs, noting the location and orientation of the parts.
31. Compress the lower shocks sufficiently to remove the shock studs from the lower mounting brackets.
32. Remove the remaining rubber bushings from the shock stud.
33. Remove the shock absorber assemblies from the vehicle.

Lower Shock Mounts

Figure 12: Rear Shock absorbers lower hardware (drive shaft removed for clarity).
34. 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.

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35. 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.

36. 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.

Figure 13: Rear Shock absorbers Upper hardware detail.
37. Align the four holes in the upper shock mount plate with the welded nuts on the chassis mounting bracket.
38. Position the air line support bracket over the two holes on the inboard side of the mount plate.
39. 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.

40. 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.

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41. 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.

Figure 14: Rear Shock absorbers Lower hardware detail.
42. Route the height sensor harnesses forward to the connector on the vehicle harness.

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Shock Absorber
Dust Cover

Electrical Connector

Figure 15: Rear Suspension Harness Connector looking from the inside outward.
(Street side shown)
43. Inspect the height sensor harness connector on the vehicle side of the harness.
a) Inspect the terminals and barrels of the connector for corrosion.
b) If the terminals are lightly corroded, they should be cleaned. If the terminals are heavily corroded the
connectors should be replaced. On the vehicle side replacing the harness connector involves splicing a
new connector/harness wire NF P/N 691560 into the vehicle harness.
44. After ensuring the connector terminals are in good condition, they may be sealed with shrink tube. Figure 8.
a) Slip a 2.5” length of shrink tube NF P/N 5940526 over one of the connector halves.
b) Apply dielectric grease NF P/N 8111767 to the connector terminals.
c) Join the two halves of the connector and secure the two halves of the connector using the threaded collar.
d)

Center the shrink tube over the electrical connector and carefully heat until tightly secured around the
connector.

e) Secure the heat tube at each end using two tyraps NF P/N 5962614.

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45. Secure the harness to the structure using the original hardware.
46. Repeat the dust cover installation as well as the inspection and shrink tube process on the other side of the
rear suspension.
47. Lower the bus in accordance with the New Flyer Service Manual.
48. Turn the main battery disconnect switch to the “ON” position.
49. Perform a ride height sensor calibration. Refer to Section 8 of the Service Manual for the calibration procedure.
50. Road test the bus to ensure proper operation
51. Remove all tools and debris and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Replace dust covers & apply shrink tube to Smart Rider

Number of
Technician(s)
1

Hours

Labor Time
T X HR
3.0

3.0

height sensor harness connectors.

PARTS REQUIRED
Item

Part Number

1

6482203

Description
SENSOR ASSY W/DUST COVER-RIDE

Qty.
per
Coach
4

Units

9

EA

Notes

EA

HEIGHT
2

5955945

TYRAP – 14.0 BLACK

3

5928660

NEVER SEIZE

0.03

EA

1

5940526

BS HEAT SHRINK.75BK (4 LENGTH)

1.0

FT

2

5962614

TYRAP-4.0 BLACK

8

EA

3

8111767

ANTI-CORROSION COMPOUND NYK-77

0.015

EA

5

691560

CBL-STRAIGHT ECOLINK CABLE

AS REQUIRED

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

Qty.

Description

Units

Notes

1

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