INSTRUCTION TO SERVICE
ITS-61178

10/18/2024

SECTION:

204 - Rear Suspension

SUBJECT:

Retrofit breather system to ZF AVE-130 Axle.

ISSUE:

Updated axle assemblies require a breather system.

SUMMARY:

Install new breather hoses, brackets and breather boxes on each side of the
center axle.

ITS-61178
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
ITS-61178

PROCEDURE:
1. Check the new AVE-130 axle for encoder brackets. If encoder brackets are already installed,
a)

Remove the cable ties that secure the encoder cable and speed sensor cable to the encoder bracket,

b)

Remove and set aside the p-clamp and hardware that secure the speed sensor cable.

c) Remove the four screws that hold the encoder cable connector to the encoder bracket and move the
encoder cable aside.
d) Unbolt the encoder bracket and discard.
2. Repeat step #1 on the other side of the axle.

Figure 1: Existing Encoder Bracket (Curbside Shown)
3. Install a new encoder bracket NF P/N 1068792 on the curbside of the axle using two bolts NF P/N 230663
bolts, two washers NF P/N 10W04000. A spacer NF P/N 707967 is required between the encoder bracket
and the axle motor casing on the upper bolt. Install a p-clamp NF P/N 247221 under the lower bolt to secure
the speed sensor cable Figure 2.
4. Attach the encoder and speed sensor cables to the encoder bracket using four cable tie mounts NF P/N
291987 attached to the encoder bracket with four self-tapping screws NF P/N 34S00006 and four tyraps NF
P/N 5958112.
5. Attach the speed sensor connector to the encoder bracket using four screws NF P/N 34S94004.

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INSTRUCTION TO SERVICE
ITS-61178

Bolt P/N 230663
Washer P/N 10W04000
Spacer P/N 707967

Encoder Bracket
P/N 1068792

Cable Tie Mount P/N
291987
Tyrap P/N 5958112
Screw P/N 34S0006

Bolt P/N 230663
Washer P/N 10W04000
P-Clamp P/N 247221

Figure 2: New Curbside Encoder Bracket Installation.
6. Install a new encoder bracket NF P/N 1068793 on the streetside of the axle using two bolts NF P/N 230663
bolts, two washers NF P/N 10W04000. A spacer NF P/N 707967 is required between the encoder bracket
and the axle motor casing on the upper bolt. Install a p-clamp NF P/N 247221 under the lower bolt to secure
the speed sensor cable Figure 3.
7. Attach the encoder and speed sensor cables to the encoder bracket using four cable tie mounts NF P/N
291987 attached to the encoder bracket with four self-tapping screws NF P/N 34S00006 and four tyraps NF
P/N 5958112.
8. Attach the speed sensor connector to the encoder bracket using four screws NF P/N 34S94004.

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INSTRUCTION TO SERVICE
ITS-61178

Encoder Bracket
P/N 1068793

Bolt P/N 230663
Washer P/N 10W04000
Spacer P/N 707967

Cable Tie Mount P/N
291987
Tyrap P/N 5958112
Screw P/N 34S0006

Bolt P/N 230663
Washer P/N 10W04000
P-Clamp P/N 247221

Figure 3: New Streetside Encoder Bracket Installation.
9. Assemble the curb side breather box assembly.
a) Bolt the lower breather bracket mount NF P/N 1069671 to the breather assembly NF P/N 1069392 using
two bolts NF P/N 10B04008 and two washers NF P/N 10W04000.
b) Install two 45 deg elbows NF P/N 5944641 in the fittings on the top of the breather assembly. Orient the
45 deg elbows as seen in Figure 4B.
10. Assemble the street side breather box assembly.
a) Bolt the lower breather bracket mount NF P/N 1069671 to the breather assembly NF P/N 1068612 using
two bolts NF P/N 10B04008 and two washers NF P/N 10W04000.
b) Install two 45 deg elbows NF P/N 5944641 in the fittings on the top of the breather assembly. Orient the
45 deg elbows as seen in Figure 4B.

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INSTRUCTION TO SERVICE
ITS-61178

45 Deg Elbows
P/N 5944641

Breather Assembly
P/N 1069392 (curbside)
P/N 1068612 (streetside)

Lower Breather Bracket Mount
P/N 1069671

Bolts & Washers

Figure 4: Breather Assembly. (Curbside shown)

Figure 4B: Orientation of 45 Deg Elbows.
11. On each side of the axle forward of the drive motor, install a upper breather bracket NF P/N 1069725 using a
bolt NF P/N 015341 and hardened washer NF P/N 20W10000. Torque the mounting bolt to 174 Ft-Lbs (Dry).
Figure 5.

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INSTRUCTION TO SERVICE
ITS-61178

Upper Breather Bracket
NF P/N 1069725

Bolt & Washer

Figure 5: Upper Breather Bracket Installation (Curbside shown)
12. Mount the curbside and streetside breathers assembled earlier to the axle on their respective sides using two
bolts NF P/N 015341 and two hardened washers NF P/N 20W10000. Torque the mounting bolts to 174 Ft-Lbs
(Dry)
13. Secure the breathers to the upper breather brackets using a bolt NF P/N 10B04008 and a washer NF P/N
10W04000.
14. Attach a breather shroud NF P/N 1069684 to the curbside breather using three rivets NF P/N 51R03007.
15. Attach a breather shroud NF P/N 1068614 to the streetside breather using three rivets NF P/N 51R03007.
Bolt NF P/N 10B04008
Washer NF P/N 10W04000

Bolts NF P/N 015341
Washers NF P/N 20W10000

Figure 6: Breather Installation (Curbside)

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INSTRUCTION TO SERVICE
ITS-61178

Rivets
NF P/N 51R03007

Breather Shroud
NF P/N 1069684 (Curbside)
NF P/N 1068614 (Streetside)

Figure 7: Completed Breather Installation (Curbside Shown)
16. Install a breather hose NF P/N 1068662 on each of the breather ports on the rear ward facing side of the
curbside drive motor. Using a backup wrench install and torque the fitting nuts 28 – 31 Ft-lbs.
17. Install a breather hose NF P/N 1068662 on each of the breather ports on the rear ward facing side of the
streetside drive motor. Using a backup wrench install and torque the fitting nuts to 28 – 31 Ft-Lbs.
18. Route the breather hoses over the tops of the electric drive motors towards the previously installed breather
assemblies. The breather hose from the wheel side breather connection on the motor housing should be
routed to the rearward connection point on the breather assembly.

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INSTRUCTION TO SERVICE
ITS-61178

Breather Hoses
P/N 1068662

Breather Hose
Connections

Figure 8: Breather Hose attachment at Motor (Curbside Shown).
19. Attach the breather hoses to the 45 deg elbows on the breather assemblies. Using a backup wrench install
the nuts on the hose fittings ant torque to 11 -13 Ft-Lbs.
20. Secure the breather hoses to the two mounting locations on the encoder brackets using a 0.750 P-clamp NF
P/N 092586 secured with a screw NF P/N 34S00006.
21. Repeat the breather hose routing and securement on the other side of the axle. The two installations are
mirror images of each other.

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INSTRUCTION TO SERVICE
ITS-61178

Breather Hose
Attachment Points at
Breather Assembly.

P-clamps
P/N 092586

Figure 9: Breather Hose Routing (Curbside Shown)
22. This completes the breather assembly install on the AVE-130 axle.

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INSTRUCTION TO SERVICE
ITS-61178

LABOUR ESTIMATE
Operation
1

Number of
Technician(s)
1

Install breathers on AVE-130 axle

Hours
0.50

Labor Time
T X HR
0.50

PARTS REQUIRED
Description

Qty.
per
Coach
1

Units

Item

Part Number

1

1068792

ASSY-BRACKET, ENCODER CABLE, CS

2

230663

BOLT-M6 X 1 X 20 CL10.9

4

EA

3

10W04000

WASHER-FLAT 1/4 NOM

4

EA

4

707967

SPACER-1.2" OD X .2" THK SST

2

EA

5

247221

CLAMP-P 0.500

2

EA

6

291987

TIE-CABLE MOUNT

8

EA

7

34S00006

SCREW PH CROSS RECESS TPG. TYPE

12

EA

TYRAP-7.0 BLACK

8

EA

SCREW TYPE F

8

EA

Notes

EA

F #10 24 UNC X 3/8" LG.
8

5958112

9

34S94004

10

1068793

ASSY-BRACKET, ENCODER CABLE, SS

1

EA

11

1069392

ASSY-BREATHER CTR AXLE CS

1

EA

12

1068612

ASSY-BREATHER CTR AXLE SS

1

EA

13

10B04008

BOLT HEX 1/4" 20 UNC X 1/2" LG

6

EA

14

10W04000

WASHER-FLAT 1/4 NOM

6

EA

15

5944641

ELBOW 45? 1/4" PT X -4 JIC

4

EA

16

1069671

BRACKET-BREATHER LWR MOUNT CTR

2

EA

2

EA

BOLT-M16 X 1.5 X 30 CL8.8

6

EA

WASHER FLAT HARDENED 5/8"

6

EA

AXLE
17

1069725

BRACKET-BREATHER UPPR MOUNT CTR
AXLE

18

015341

19

20W10000

20

1069684

SHROUD-BREATHER CTR AXLE CS

1

EA

21

1068614

SHROUD-BREATHER CTR AXLE SS

1

EA

22

51R03007

RIVET MONO BLIND SS 3/16" X .064/.270

6

EA

23

1068662

ASSY-HOSE 387-04 FL45

4

EA

24

092586

CLAMP-P 0.750

4

EA

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INSTRUCTION TO SERVICE
ITS-61178

SPECIAL TOOLS REQUIRED
Item
1

ITS-61178

Part Number

Qty.

Description

Units

Notes

No Special Tools Required

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