NAYVISTAR

FIELD SERVICE CAMPAIGN - 24101
29 January 2024

SUBJECT:
Driveline Motor Yoke Castle Nut Torque

MODELS INVOLVED:
IC Bus® Electric CE Series school bus

DEFECT DESCRIPTION:
On certain IC Bus® Electric CE Series school bus, the drive motor yoke castle nut may
not have been tightened to its specified value at time of assembly.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service Portal™
with FSC 24101. Also complete any other open campaigns listed on the Service Portal
at this time.

TOOLS REQUIRED:
No special tools required.

PARTS REQUIRED:

Part Number Description Quantity
2500674C91 U-JOINT KIT, DRIVESHAFT 4
N/A Cotter Pin 5mm x 60mm Source Locally

Table 1 Parts Information

WORK INSTRUCTIONS

WARNING! To prevent personal injury or death, NEVER service a high-voltage
vehicle without completing High-Voltage Safety training. Before working on
vehicle, read and obey all High-Voltage Safety and Lock-Out Tag-Out procedures
and information.

WARNING! To prevent personal injury or death, read all information in the Safety
Information and High-Voltage Safety sections of the service manual.

WARNING! To prevent personal injury and / or death, or damage to property, park
vehicle on hard flat surface, turn the engine off, set the parking brake, and install
wheel chocks to prevent the vehicle from moving in both directions.

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WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.

WARNING! To prevent personal injury and / or death, or damage to property, if
the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over.

WARNING! To prevent personal injury and / or death, or damage to property, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.

1. Park vehicle on a dry and level surface.
Put drive mode selector in Neutral and set parking brake.
Turn ignition to Key OFF position.

Install wheel chocks.

a Fe N

Turn 12V disconnect switch OFF. Refer to appropriate service manual for detailed
instructions.

6. Perform High-Voltage Isolation Level 1. Refer to appropriate service manual for
detailed instructions.

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0000480336

Figure 1. Universal Joint (U-Joint) Straps with Bolts (Drive Motor Yoke)

1. U-joint strap bolt (4)
2. U-joint strap (2)

NOTE: When removing or installing the universal joint (U-joint), it is possible for
the U-joint caps to slide off. Any type of tape wrapped around the top of each U-
joint cap will keep the caps in place until the U-joint is removed or installed.

7. Remove and discard four U-joint strap bolts (Figure 1, Item 1) and two U-joint straps
(Figure 1, Item 2) from drive motor yoke.

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0000480337

Figure 2. Driveshaft Safety Loop

1. Driveshaft
2. Safety loop

NOTE: When disconnecting one end of driveshaft, make sure you support the
driveshaft, so it is not damaged. You may use a suitable lifting device to lower the
driveshaft end and support the driveshaft with a safety loop already in place.

NOTE: A pry bar may be used if the U-joint will not come out of the yoke. Gently
pry the U-joint out of its seat to aid in removal.

8. Using a suitable lifting device, remove driveshaft yoke from drive motor yoke and
lower driveshaft end from drive motor yoke onto lifting device.

9. Rest driveshaft on safety loop (Figure 2, Item 2).

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Figure 3. Drive Motor Yoke with Castle Nut

1. Castle nut
2. Cotter pin
3. Drive motor yoke

10. Remove and discard cotter pin (Figure 3, Item 2) from drive motor yoke (Figure 3,
Item 3) and castle nut (Figure 3, Item 1).

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a

0000480339

Figure 4, Adjustable Wrench Holding Yoke

1. Adjustable wrench
2. Yoke

NOTE: The yoke on the drive motor will spin when torquing the castle nut. You
may use a spanner wrench or an adjustable wrench to hold the yoke from
spinning. Refer to Figure 4.

NOTE: When torquing the castle nut, start with the lowest torque value in the
range and gradually raise the torque value until the slots in the castle nut line up
with the hole in the cotter pin.

11. Using torque wrench, tighten castle nut to 90-110 Ib-ft (66-81 Nem).
12. Install new cotter pin.

13. Lift driveshaft into position. Insert driveshaft U-joint into drive motor yoke and install
new U-joint straps and bolts.

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14. Using torque wrench, tighten U-joint strap bolts to 45 Ib-ft (62 Nem).

15. Install all appropriate Manual Service Disconnects (MSD) that were removed in
Step 6. Refer to appropriate service manual for detailed instructions.

16. Turn ON 12V disconnect switch. Refer to appropriate service manual for detailed
instructions.

17. Turn ON high-voltage disconnect switch. Refer to appropriate service manual for
detailed instructions.

18. Remove wheel chocks.

LABOR INFORMATION

Operation number must appear on all claims.

Operation Number Description Time
A40-24101-1 L1 Disconnect, R&R driveshaft & tighten castle nut 0.8 hr

Table 2 Labor Information
WARRANTY CLAIMS

Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner, making reference to Field Service Campaign 24101.

Section 7 of the Warranty Policy and Procedures Manual contains further information
related to the submission and processing of AFC / Recall claims.

As with all claim submissions, items acquired locally must be submitted in the “Other
Charges” tab. The cost of any bulk items (such as a bag of cable tie straps, roll of wire,
barrel of oil, or tube of silicone) should be prorated for the cost of the individual pieces /
amount used during each repair.

To make sure that this important improvement is made in a timely manner, all claims for
24101 activity must be submitted by 29 January 2025 or within the normal warranty
period for the component, if after 29 January 2025.

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