INSTRUCTION TO SERVICE
ITS: 60578

November 24, 2022

SECTION:

204-Rear Suspension

WRITTEN BY:

Troy Stutsky
Inspect Tag Axle Air Spring Mounting Brackets for Incorrect Bracket. Replace
the Tag Axle Air Spring Mounting Bracket “If Required”.
Some coaches could have been built with the wrong tag axle air spring bracket.
This could over-extend the shocks or allow the shocks to hit their internal stops.
Both situations can damage the shock.
Suspect coaches will be inspected. If the coach is affected, the tag axle air
spring bracket will need to be replaced.

SUBJECT:
ISSUE:
SUMMARY:
AFFECTED MODEL:

J Model Coaches

ITS60578
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED 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 unauthorized disclosure,
reproduction or other distribution of this document or information 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.

INSTRUCTION TO SERVICE
ITS60578

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Inspect both the LH & RH the tag axle air spring mounting brackets by looking over the tag tire and noting the
height of the flange seen below. The J coaches should have a flange height of 2.26” as shown in Figure 1.

Figure 1: Correct Flange Height of Tag Axle Air Spring Mounting Brackets for J Model Coaches = 2.26”
4. If the flange height is correct at 2.26” on the J Model coach, this tag axle air spring mounting bracket is correct
and no further action is needed on it.

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INSTRUCTION TO SERVICE
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5. If the flange height is incorrect at 1.21” on the J Model coach, this tag axle air spring mounting bracket is
incorrect and will need to be replaced.
6. To replace the incorrect tag axle air spring mounting bracket, please follow these steps:
a.

Lift the coach about 1-2“ of the ground using Rotary lifts on the front and drive wheels. See Figure 2.

Figure 2: Lifting the Coach
b.

Remove & retain tag axle wheel & wheel nuts. See Figure 3.

Figure 3: Remove Tag Axle Wheel

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INSTRUCTION TO SERVICE
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c.

Pull loom back and disconnect tag axel blue ½ OD airline tube from 90º elbow brass fitting. See Figure 4.

Figure 4: Disconnect Air Line
d.

Remove & retain the tag axle air spring assembly and hardware from the coach structure by removing
hex long cap screws, spring lock washers, and flat washers (6 places). The air spring assembly will drop
down on Tag axle plate by its weight. See Figure 5.

Figure 5: Unfasten the Tag Axle Air Sring Assembly

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INSTRUCTION TO SERVICE
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e.

With the air spring assembly resting on the tag axle plate, push down on the air spring assembly and
remove & retain the lock nuts & wahers that fasten the tag axle mounting bracket to the existing air
spring. Discard the mounting bracket and replace it with the correct mounting bracket for the J Model
coaches (PN 12-04-1229). Fasten the new mounting bracket to the existing air spring using the existing
hardware. Torque the two lock nuts to 40 – 50 Ft/Lbs, (Not to exceed 50Ft/Lbs). See Figure 6.



NOTE: Prior to installation, apply a thin layer of sealant (PN 21-7203-2) to external pipe threads of all

fittings leaving the three leading threads bare.

Figure 6: Remove & Replace Tag Axle Air Spring Mounting Bracket
f.

Raise and mount the tag axle air spring assembly to the coach structure and fasten with hex long cap
screws, spring lock washers, and flat washers removed in step d Figure 5. Add 1 – 2 drops of blue
Loctite (PN 21-7212-18) to the threads of the hardware and torque hardware to 17 ± 2 Ft/Lbs. See Figure
5.

g.

Connect blue ½ OD airline tube from ECASII rear pressure sensor to 90º elbow brass fitting on tag axle
air spring. Fully position loom onto the airline tube and secure with electrical tape.

h.

After installing the tag axle air spring assembly apply Sikaflex (PN 21-7112-31) all around and between
the air spring mounting bracket and the frame. Touch up any bare metal areas on the bracket and the
frame with undercoating.

7. Re-install the tag axles wheels using the procedure in Appendix A.
8. Lower the coach and remove the rotary lifts from the coach.
9. Complete an air leak test after installation has been completed.
10. Remove all tools and debris and return the coach to service condition.
11. Turn the main battery disconnect switch to the “ON” position.

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INSTRUCTION TO SERVICE
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LABOUR ESTIMATE
Operation
1

Inspect LH & RH Tag Axle Air Spring Mounting

Number of
Technician(s)
1

Hours
0.25

Labor Time
T X HR
0.25

Brackets for Incorrect Brackets
2

Replace One Tag Axle Air Spring Mounting Bracket

1

1.25

1.25

3

Replace Both the LH & RH Tag Axle Air Spring

1

2.5

2.5

Mounting Brackets

PARTS REQUIRED
Qty.
per
Coach
2

Units
EA

If Required

Item

Part Number

Description

Notes

1

12-04-1229

BRACKET ASM-AIR SPRING,TAG AXLE

2

21-7203-2

SEALANT-PIPE FITTING

0.01

EA

If Required

3

21-7212-18

ADHESIVE-LOCKTITE THRD-LOCKING

0.01

EA

If Required

4

21-7112-31

SEALANT-SIKAFLEX,GREY,221,11OZ

0.01

EA

If Required

SPECIAL TOOLS REQUIRED
Qty.

Units

Notes

ROTARY LIFT

1

EA

Source Locally

NPN

OPEN WRENCH

1

EA

Source Locally

3

NPN

TORQUE TOOLS

1

EA

Source Locally

4

NPN

WHEEL INSTALLATION TOOLS

1

EA

Source Locally

5

NPN

ELECTRICAL TAPE

0.01

EA

Source Locally

5

NPN

UNDERCOAT

0.01

EA

Source Locally

6

NPN

ANTISEIZE COMPOUND

0.01

EA

Source Locally

Item

Part Number

1

NPN

2

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Description

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Appendix A

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