ISSUE DATE:

07/07/2023

REVISION DATE:

09/28/2023

SERVICE BULLETIN SUBJECT:

Duo Power Gearbox Single Turn Snap Ring Field Retrofit

VINs or MODELS AFFECTED:

Service Specified Buses

COMPLETE BY:

See Warranty Disclaimer

SERVICE BULLETIN #:

SC-23-085

LABOR OPERATION CODE:
PP59Z
Warranty Disclaimer: SC-23-085 is the solution to a systemic failure issue in the DuoPower gearbox. Repair
labor reimbursement is available through Proterra's Warranty Portal. Oridinary Proterra Warranty policies
applied. Failure to complete this repair within 180 days after retrofit kit shipment date may result future claims
against the gearbox (Proterra PN: 050817) being rejected.
This document should be retained and referred to for future maintenance until the Proterra Parts and/or
Maintenance Manual is updated to reflect work done as a result of this document. Please ensure that this
document is available for parts and maintenance staff.

1
2
3
4
5
6
7
9

Operation
Step 1 – Step 14
Step 15 – Step 20
Step 21 – Step 33
Step 34 – Step 59
Step 60 – Step 79
Step 80 – Step 92
Step 93 – Step 97
Step 98 – Step 105 (FiF)

Labor Table
Number of Technicians
1
1
1
1
1
1
1
1
Total Labor Time

Hours
1.5
1
3
6
3
2
1.5
1

Labor Time (T x H)
1.5
1
3
6
3
2
1.5
1 (FiF)
18

Duo Power Gearbox Single Turn Snap Ring Field Retrofit
Description:
The procedure describes the process of updating the gearboxes from a dual turn to a single turn snap
ring.

Note:
This campaign document must be printed in colored ink unless crucial information could be
misunderstood.
1 | Page
Headquarters: 1815 Rollins Road, Burlingame, CA 94010
East Coast Manufacturing: 1 Whitlee Court, Greenville, SC 29607
West Coast Manufacturing: 383 Cheryl Lane, City of Industry, CA 91789

DuoPower Gearbox Snap Ring Replacement Procedure
This procedure details the replacement of a snap ring in each gearbox.

Table 9-1: Proterra Supplied Required Parts Kit

Proterra PN

065000

2

Snap Ring
Replacement

050279

Bolt Gearbox Mount, Gearbox, Axle
(Larger GB Front Housing Bolts)

20

Gearbox to Axle
Cradle Mounting

129-5217

M8X1.25X45/22-10.9 HHCS
(Smaller GB Front Housing Bolts)

26

Gearbox Front
Hosing Cover
Mounting

Table 9-2: Required Shop Supplies

Description

Loctite®, 222, 243, 263

QTY

1 each

Use

Multiple

Brake Cleaner (or equivalent)

1

Mounting Thread Preparation

Torque Stripe Marker

1

Torque Marking/Gearbox Procedure
Completion Marking

Cable-Ties, Black
Coolant Fill Hose, 3/8” EPN

Proterra Operating Company, Inc.

Snap Ring
Replacement

Ring, Internal, 65.58 OD X 5.08 RAD.
Wall X 1.93 Thick (Single Turn Snap Ring)

NOTE: The traction motor pairing procedure is necessary if a motor is replaced or
if the motor does not pair automatically when re-installed.

ATTENTION: Each gearbox front housing cover must be re-installed on the same
gearbox it was removed from or gear damage may occur.

1

Use

187-3024

NOTE: This procedure does not require axle or gearbox removal.

Electrocution hazards exist that could cause serious injury or death.
Perform the Proterra High-Voltage Lockout/Tagout procedure as detailed in
!
WARNING the vehicle's Maintenance Manual when instructed.

QTY

- Service Retrofit Kit, DuoPower, SingleTurn Snap Ring

Procedure Overview:
• Remove both traction motors.
• Separate each gearbox front housing cover from each gearbox.
• Remove and replace a snap ring on each gearbox front housing cover.
• Reinstall each gearbox front housing cover to its original gearbox.
• Reinstall both traction motors.

Description

Multiple

Cable/Hose Securement

1

Coolant Fill

Coolant, 50/50 Ethylene Glycol/
Distilled Water Mixture

Varies

Coolant Fill

Transmission Fluid, Eaton

8-10 L

See Approved Gearbox Fluids Table
for approved alternatives

9-171

Table 9-3: Tools

Description

QTY

Description

Use

QTY

Use

Tag, Plastic Lockout

1

Lock-out/Tag-out

Screwdriver, Flathead:
Small, Large

1 each

Multiple

Padlock, Orange Lockout

1

Lock-out/Tag-out

Screwdriver, Phillips #2

1

Multiple

Lockout, Grip-cinching Cable

1

Lock-out/Tag-out

Pliers, Needle-nose

1

Snap Ring Removal

Wrench, Ratchet, 10 mm (Long)

1

Traction Motor Mounting

Compressed Air w/Nozzle

1

Mounting Thread Preparation

Wrench, Ratchet, 10 mm (Short)

1

Traction Motor Mounting

Step-stool

1

Multiple

3/8” Drive Torque Adapter - 10 mm
Vendor: Matco Tools
VPN: BTA10M

1

Traction Motor Mounting

Snips, Flush-Cut

1

Abrasion Control

Tool, Wrench, 7/8”

1

Gearbox Outlet Oil Hose Fitting

Tool, Wrench, 1”

1

Oil and Coolant Hoses

Tool, CrowFoot, 30mm, 1/2” Drive
Vendor: MSC Industrial Supply
VPN: 16679995 (if available)

1

Phase Cables Cord Grip Caps

Large Adjustable Wrench

1

Torque Wrench, In-lbs

Table 9-4: Approved Gearbox Fluids

Manufacturer

Product

Allied Oil and Tire Co.

Allied Syntx MTF 7000 Synthetic Transmission
Fluid

Bardahl de Mexico S.A. de C.V.

Bardhl Gear Oil MTF Fully SYN PS-386

BASF Corporation

EMGARD MTF 7000

Coolant Hose

BG Products, Inc.

SAE 40 Full Synthetic Transmission Oil

1

Multiple/18-53 in-lbs

BP Lubricants USA Inc.

Transmax Manual E Longlife 40

Torque Wrench, Ft-lbs

1

Multiple/8-80 ft-lbs

Chevron Products

Delo® Syn-trans XE SAE 75W90

Ratchet, 1/4”

1

Multiple

Chrysan Industries

Chrysan PS-386 MTF

Ratchet, 3/8”

1

Multiple

CHS Incorporated

Maxtron MT 40

Citgo Petroleum Corp

Breaker Bar/Long Handle Ratchet,
1/2” Drive

1

Oil Filter Caps

Syndurance Synthetic MTF
Mystik SX-7000 Synthetic MTF

Comercial Importadora S.A. de
C.V.

Synquest CD 50

Impact Driver, 1/2, 3/8”
Ratchet, Electric, Right-Angle, 1/4”
Extension Variety, 1/4, 3/8, 1/2”

1 each

Multiple

1

Multiple

Comercial Roshfrans, S.A. de
C.V.

Gear Plus CD-700 (Synthetic Transmission Fluid)

1 each

Multiple

David Weber Oil Co

Gibraltar Syngear PS-386 SAE 40

Oil Filter Caps

Exxon Mobil Fuels and
Lubricants

Mobil Delvac 1 Transmission Fluid 40

Federated Co-Operatives Ltd.

MTA EA Synthetic

Fuchs Petrolub

Fuchs Titan Cytrac ETN SAE 40

Industrial Villanueva, S.A. DE
C.V.

Invisa Synthetic Oil Gear AC SAE 75W-90

Lubrication Engineers, Inc

Synolec Transmission Fluid SAE 40 (640)

Mercedes-Benz Australia/
Pacific Pty Ltd