INSTRUCTION TO SERVICE
ITS: 60966

April 2024

SECTION:

400-Structures

WRITTEN BY:

Troy Stutsky

SUBJECT:

Inspect Center Axle Radius Rod Support Castings

ISSUE:

SUMMARY:

The lower radius rod mounting holes may have been located incorrectly during
production of the parts and may be too close to the wall of the casting which
could possibly cause the casting to crack at the lower radius rod mounting
holes. Both the streetside (SS) & curbside CS) castings could be affected
Use a Go/No Go tool to determine if the location of the lower radius rod
mounting holes is suspected to be incorrect on both the streetside (SS) &
curbside (CS) center axle radius rod support castings.

ITS60966
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
ITS60966

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
WARNING: Raise the bus in accordance to the “Raising the Vehicle” procedures and precautions that
are outlined in your New Flyer Service Manual. Follow all shop procedures and safety practices while
raising the bus. Use proper PPE per shop requirements.
3. Locate the center axle bulkhead assembly that is directly in front of the center axle and then locate the SS
and CS center axle radius rod support castings. See Figure 1.

CS Casting

Center Axle
(Ref)

Front of Bus

SS Casting

Figure 1: SS & CS Center Axle Radius Rod Castings (View from Under Bus)
4. Using the supplied “Go / No Go Tool”, check the clearance between the lower radius rod and the casting wall.
The tool has two different end sizes etched on it (thick end is 0.3789” & thin end is 0.2647”) see Figure 2. It is
important to insert the correct end size on the correct side of the radius rod end. See Figure 3 and 4 for the
correct locations to insert the correct end of the tool.

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Figure 2: Go / No Go Tool
Insert 2647
End

Insert 3789
End

Insert 3789
End

Insert 2647
End

SS Casting

CS Casting

Front of Bus

Figure 3: How to Measure for a Pass or Suspect Casting (View from Under Bus)

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INSTRUCTION TO SERVICE
ITS60966

SS Casting

CS Casting

Figure 4: Enlarged View of Gap to Measure

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INSTRUCTION TO SERVICE
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5. If the tool can be inserted into all four gap locations as shown in Figures 3 and 4 on both the SS and CS
center axle radius rods support castings, this bus is a pass and can go back into service. Please complete the
inspection document in Appendix A and document that the bus has been inspected and is a pass.
6. If the tool can’t be inserted into any one of the gap locations as shown in Figure 3 and 4 on both the SS and
CS center axle radius rods support castings, please follow these instructions:
a.

On the inspection document in Appendix A, mark which location(s) were a pass and which location(s) are
suspect. If either the SS or CS has one suspect gap, that lower radius rod will need to be removed from
the center axle radius rod support casting side only and the mounting holes in the casting will need to be
further inspected.

b.

Once the lower radius rod has been removed from the casting in the suspected mounting location, the
mounting hole walls will need to be measured using a caliper. If the mounting hole wall thickness is
LESS than the minimum thicknesses shown in Appendix A, the casting is not a pass and the bus will
require to be reworked using the instructions documented in ITS-60969 before going back into
service. ITS-60969 to rework the center axle radious rod support castings can be obtained from your
New Flyer Regional Product Support Manager.

c.

Once the lower radius rod has been removed from the casting in the suspected mounting location, the
mounting hole walls will need to be measured using a caliper. If the mounting hole wall thickness is
EQUAL to or MORE than the minimum thicknesses shown in Appendix A, the casting is a pass and the
radius rod can be reinstalled and the bus can go back into service.

d.

Ensure the lower radius rod mounting holes in the casting are clean and free from any debris. Fasten the
radius rod to the center axle radius rod support casting using two washers (NF PN 6407959), two
spacers (NF PN 6490019) and two bolts (NF PN 6490020) per radius rod end. Apply a thin layer of
Never Seize (NF PN 5928660) to the mounting surfaces of the washers, spacers and to the entire length
of the bolt and under the bolt head. Ensure only a thin layer is applied and wipe off any access.
Assembled bolted connection as shown in Figure 6 and torque the hardware to 300Ft/Lbs.

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INSTRUCTION TO SERVICE
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Bolt
Spacer

Radius Rod

Washer

Figure 6: Radius Rod Hardware Stack Up
7. Clean up all tools and debris and return the bus to service condition.
8. Safely lower the bus and turn the main battery disconnect switch to the “ON” position.

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INSTRUCTION TO SERVICE
ITS60966

LABOUR ESTIMATE
Operation
1

Inspect Center Axle Radius Rod Support Castings with

Number of
Technician(s)
1

Hours
0.5

Labor Time
T X HR
0.5

1

1.0

1.0

Go/No Go Tool
2

Remove & Install Radius Rod to Inspect Suspect Lower
Radius Rod Mounting Holes

PARTS REQUIRED

Description

Qty.
per
Coach
0.01

Units
EA

Source Locally

Item

Part Number

Notes

1

5928660

NEVER SEIZE

2

6407959

WASHER

4

EA

Order As Required

3

6490020

BOLT-M18 X 1.5 X 100

4

EA

Order As Required

4

6490019

SPACER-BUSH 32 L X 38 O.D. X 20.6 ID

4

EA

Order As Required

SPECIAL TOOLS REQUIRED

Item

Part Number

1

NPN

Description
GO / NO GO TOOL

Qty.

Units

Notes

1

EA

Supplied by
New Flyer
Service

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Appendix A

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Appendix A

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