ORIGINAL CREATION DATE:
SERVICE BULLETIN SUBJECT:
VINs or MODELS AFFECTED:
COMPLETE BY:
SERVICE BULLETIN #:
LABOR OP CODE:

06/14/2023
DuoPower Gearbox Oil and Filter Samples
Service Specified Buses
Next Service Opportunity
FC-23-094
PP60Z
Labor Table

Operation
1

Step 1 – Step 23

Number of
Technicians

Hours

1
1.5
Total Labor Time

Labor Time
(T x H)
1.5
1.5

DuoPower Gearbox Oil and Filter Samples
Retrofit Description:

This procedure describes the process of acquiring oil and filter samples from the Duopower
gearboxes.

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Tools/Parts Required:

Tools and Supplies Required:
10mm Socket
13mm Socket
Torque Wrench
Fluid Fill Pump
Marker
500mL Liter Sample Bottle

4 EA

Plastic Bag (Small)

2 EA

Plastic Bag (Large)

1 EA

Gearbox Oil (Not Supplied)

2-10 Qts

Kit Parts Required:
052501

OIL FILTER, REPLACEMENT KIT, OIL COOLER, GEARBOX, EMP

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Procedure:
1.

2.

3.

Prepare oil sample containers by labeling with:
a.

The last 4 digits of VIN

b.

Bus Side Location (CS or SS)

c.

Milage accumulated on the gearbox oil (from last oil change)

d.

Sample Number (1 or 2)

Prepare oil filter sample bags by labeling with:
a.

The last 4 digits of VIN

b.

Bus Side Location (CS or SS)

c.

Milage accumulated on the gearbox oil (from last oil change)

Drive for approximately ten (10) miles to bring the vehicle up to operating temperature and to
adequately stir up the fluid in the gearbox casing.
NOTE: Be prepared to drain the fluid immediately after shutdown while the fluid is still at
normal operating temperature.

4.

Using four Wheel Lifts, raise the bus into the air. Using four Jack Stands, support the bus for
safety.

5.

Gain access to the street side gearbox oil drain plug on the bottom side of the gearbox.

6.

Place catch pan underneath the gearbox oil drain plug.

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7.

Remove the drain plug and allow 2 seconds of fluid to drain before collecting oil in sample
containers.
NOTE: Make sure to collect oil in the containers in the order labeled on the containers as
“Sample Number”.

8.

Collect 500mL of oil in each of the sample containers as the oil drains out of the gearbox.

9.

Analyze the oil in the sample containers. If the oil contains particles of the decaying filter,
ensure all the street side gearbox oil has been drained.

10.

Reinstall the drain plug.

11.

Discard the oil that was initially drained and not caught with sample container.

12.

Repeat Step 5-11 for the curb side gearbox oil.

13.

Remove the DuoPower front/rear cover plates and top plates to provide access to the system.
Retain fasteners for reinstall.

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14.

Remove and inspect the street side oil filter. Place the filters in the labeled bag taking care not
to contaminate the filter with any outside debris. If the oil filter is decaying, ensure all the
street side gearbox oil has been drained.
NOTE: The Oil Module is located on the Street Side of the DuoPower axle. The filter
physically located towards the curb side is the Street Side oil filter. The filter located towards
the Street Side is the Curb Side oil filter.

15.

Remove and inspect the Street Side wire mesh filter. Clean off any debris if necessary and
reinstall. If filter debris is found in the wire mesh filter, all of the gearbox oil will need to be
replaced.
NOTE: The Street Side prefilter is located on the lower side of the module while the Curb
Side prefilter is located on the upper side.

16.

Repeat Steps 14-15 for the Curb Side Gearbox.

17.

Install the 2 new oil filters.

18.

Install the Oil Filter Caps. Torque the to 200 ft-lbs (270 Nm).

19.

Install the Mesh Prefilter Caps. Torque the to 155 ft-lbs (210 Nm).

20.

Check and clean the street side drain plug and then install drain plug into the bottom of the
gearbox. Torque drain plug to 18 ft-lbs.

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21.

Remove the street side gearbox fill plug.

22.

Using a fluid fill pump with angled fill tip, fill the street side gearbox with the recommended
fluid until seen in the sight glass.
NOTE: Gearbox fluid alternatives shown in Appendix A.

23.

Apply a small amount of gearbox oil to the O-ring seal on the fill plug and then install the
street side gearbox fill plug. Torque to 13 ft-lbs (18 Nm).

24.

Repeat Steps 20-23 for the Curb Side Gearbox.

25.

Run both the Street Side and Curb Side oil pumps to purge any air from the system.

26.

If necessary, top off gearbox oil until fluid is seen in both sight glasses.

27.

Install the removed axle panels with the retained fasteners.

28.

Remove the Jack Stands and lower the bus using the Wheel Lifts.

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Appendix A: Gearbox Oil Alternatives
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

BG Products, Inc.

SAE 40 Full Synthetic Transmission Oil

BP Lubricants USA Inc.

Transmax Manual E Longlife 40

Chevron Products

Delo® Syn-trans XE SAE 75W90

Chrysan Industries

Chrysan PS-386 MTF

CHS Incorporated
Citgo Petroleum Corp

Maxtron MT 40
Syndurance Synthetic MTF
Mystik SX-7000 Synthetic MTF

Comercial Importadora S.A. de C.V.

Synquest CD 50

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

Gear Plus CD-700 (Synthetic Transmission Fluid)

David Weber Oil Co.

Gibraltar Syngear PS-386 SAE 40

Exxon Mobil Fuels and Lubricants

Mobil Delvac 1 Transmission Fluid 40

Federated Co-Operatives Ltd.
Fuchs Petrolub

MTA EA Synthetic
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

Alliance Prime Trans Plus 40

Navistar

Fleetrite PS-386 Synthetic Manual Transmission Lubricant

Northland Products Co.

Northland Synergy Synthetic® ExP Transmission 50

Petro-Canada Lubricants Inc.

TRAXON E Synthetic MTF (Synthetic Transmission Fluid)

Phillips 66 Company

Triton® Synthetic MTF
Kendall SHP® Synthetic MTF

Quick Smart Products P/L

Road Trans MTF PS-386

Raloy Lubricantes, S.A. C.V.

Raloy Transintex Plus SAE 40

Repsol Lubricantes Y Especialidades S.A.
Royal Manufacturing Co.

Repsol Cartago LD 40
Monarch Syntran Plus SAE 40

Safety-Kleen Oil
Shell

Performance Plus Synthetic HD PS-386 Transmission Fluid
Spirax S6 GME 40

Texas Refinery

Syntex 2000 SAE40 Synthetic Manual Transmission Lubricant

The Valvoline Company

Syn Gard™ Transmission Fluid E386

Total Mexico S.A. DE C.V.

Transmission SYN 7000

TOTAL Specialties USA, Inc.

TOTAL Transmission Gear 8 FE SAE 40
America Max Full Synthetic SAE 40 Manual Transmission
Fluid
Lubriguard SAE 40 Synthetic Heavy Duty Transmission Fluid

Warren Oil

PURUS Synthetic SAE 40 Heavy Duty Transmission Fluid

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