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

4 | Page

7. Disconnect the Terminals to the License Plate Lights as shown in the following photograph.

Wiring Terminals

8. Using Side Cutting Pliers, cut any Cable Ties that attach the Trunk Panel wiring to the trunk.
9. Remove the wiring from the Trunk Panel.
10. Remove both upper Strut Retaining Clips from the Gas Struts from their attachments on the
Trunk Panel. Leave the Struts attached to the lower ball stud brackets and allow the Struts to
rest against the rear bumper.

Retaining Clip

11. Using a Jack Stand or other approved Lifting Device, support the Trunk Panel.

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

5 | Page

12. Using a 13mm Ratchet/Socket, remove the Locknuts that secure both Hinges to the Hinge
Brackets shown circled in red below.

13. Remove the Trunk Panel and safely support it for further work.

14. This completes the Trunk Panel Removal part of the procedure. Retain all the removed
hardware for reinstallation.

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

6 | Page

Inspect for Missing Components:
15. Place the Trunk Panel on a level working surface with the interior side facing upward.
16. Using the following illustration as a guide, inspect the Trunk Panel to verify that all the parts
shown are included and securely bonded to the Trunk Panel. Any loose or partially de-bonded
parts must be re-bonded. Missing or damaged parts must be replaced.

17. Verify that both Ball Stud Brackets are securely bonded to the aft wrap as shown in the
following photograph. Any loose or partially de-bonded parts must be re-bonded. Missing or
damaged parts must be replaced.

Ball Stud Bracket

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

7 | Page

18. Make a note of the parts that must be replaced. These must be ordered from Proterra Service
if they were not included in the kit.
19. The inspection process is complete.

Re-bond Missing or Damaged Components:
20. Gather any missing or damaged parts that must be replaced.
21. Using a Heat Gun and Scraper, remove any loose or damaged components from the Trunk
Panel.
22. Inspect the Ball Stud Brackets attached to the AFT Wrap of the bus. Using a Heat Gun and
Scraper, remove any Ball Stud Brackets that are loose or damaged.
23. Using a Heat Gun and Scraper, remove any excess Plexus from the areas where the missing
or damaged components were previously installed.
24. Using the following illustrations as a guide, lay out any components to be replaced onto the
Trunk Panel using the dimensions shown.

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

8 | Page

25. Using a Permanent Marker, outline each component in the position where it will be installed.
26. Using Isopropyl Alcohol and Shop Towels, clean the areas inside the marked lines.
27. Using a Power Drill with a 36-Grit Sanding Disk, scuff the bonding surface of each component.
28. Using a Power Drill with a 36-Grit Sanding Disk, scuff the areas inside the marked lines where
the components will be installed.
29. Using Super Glue, install four Bond Gap Washers (018933) near the corners of each
component to be installed.
30. Using Isopropyl Alcohol and Shop Towels, clean the bonding surface of each component to be
installed.
31. Using a Plexus Gun with a clean tip, apply adhesive to the bonding surface of one of the
components to be installed.
32. Place the component into its intended location which was marked earlier.
33. Using a Tongue Depressor, remove any excess Plexus.
34. Secure the component for curing to the bus with Duct Tape.
35. Repeat the process until each component has been bonded and secured with Duct Tape to
the Trunk Panel.
36. Allow 90 minutes for the Plexus adhesive to cure.
37. The process is complete if no Ball Stud Brackets are to be replaced.
38. Using a Heat Gun and Scraper, remove any Ball Stud Bracket that is damaged or de-bonded.
39. Using a Heat Gun and Scraper, remove any excess adhesive from the Ball Stud Bracket
areas that need are to be re-bonded.

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

9 | Page

40. Using the following illustration as a guide, place the Ball Stud Bracket in position against the
Aft Wrap for mounting.

41. Using a Permanent Marker, outline the Ball Stud Bracket in the position shown above. Also
mark the three mounting holes in the Bracket for drilling onto the bus.
42. Using a Power Drill with a 7mm Drill Bit, position the Bit in the center of one of the hole
locations. Angle the Bit slightly outboard and drill through the Return Flange as shown in the
following photograph.

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

10| Page

43. Test the drilled hole to see if the Screw (019493) will fit through the hole and allow the Locknut
(018575) to start on the Screw by hand.
44. If this is not successful, re-drill the hole with the Drill pointed more outboard. Do not damage
the Return Flange.
45. Repeat the process until all three Screws (019493) and Locknuts (018575) can be started by
hand.
46. Using a Calibrated Torque Wrench with a T-25 Torx Socket and a 10mm Combination
Wrench, torque the Screw (019493) to 34 inch pounds.
47. Repeat the process to replace the Ball Stud Bracket on the other side of the bus if needed.
48. The re-bond part of the process is complete.

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

11| Page

Wet Layup Process:
49. Place the Trunk Panel on a level working surface with gel coat surface facing down.
50. This process will begin by cutting pieces of Biaxial Fiberglass (050677) to reinforce the
Hinge Stud Plates (021156) as shown in the following illustration.

51. Using Scissors and a Tape Measure, cut a piece of Biaxial Fiberglass (050677)
measuring 205mm x 205mm,
52. Place the cut piece of Biaxial Fiberglass (050677) over the top of one of the Hinge
Stud Plates (021156). The Fiberglass sheet should be placed so that it overlaps
evenly horizontally on the Stud Plate.
53. The Biaxial Fiberglass (050677) should only overlap 15mm on the top of the Stud
Plate (021156).
54. With the Biaxial Fiberglass (050677) placed as previously described, use a Permanent
Marker to mark the positions of the Studs on the Stud Plate (021156) onto the Biaxial
Fiberglass.

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

12| Page

55. Using Scissors or an Approved Safety Knife, cut a “X” on the marked areas so that the
Studs can pass through the Biaxial Fiberglass (050677) sheet.

56. Place the Biaxial Fiberglass (050677) sheet on the Hinge Stud Plates (021156) as
shown in the first illustration in this section.
57. Using Scissors and a Tape Measure, cut a piece of Biaxial Fiberglass (050677)
measuring 255mm x 245mm.
58. Place the cut piece of Biaxial Fiberglass (050677) over the top of one of the Hinge
Stud Plates (021156). The Fiberglass sheet should be placed so that it overlaps
evenly horizontally on the Stud Plate.
59. The Biaxial Fiberglass (050677) should only overlap 15mm on the top of the Stud
Plate (021156).

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

13| Page

60. With the Biaxial Fiberglass (050677) placed as previously described, use a Permanent
Marker to mark the positions of the Studs on the Stud Plate (021156) onto the Biaxial
Fiberglass.

61. Using Scissors or an Approved Safety Knife, cut a “X” on the marked areas so that the
Studs can pass through the Biaxial Fiberglass (050677) sheet.
62. Place the Biaxial Fiberglass (050677) sheet on the Hinge Stud Plates (021156) as
shown in the first illustration in this section.
63. Repeat the entire process to cut Biaxial Fiberglass Sheets (050677) for the other Stud
Plate and place them over the Stud Plate.

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

14| Page

64. This process will begin by cutting pieces of Biaxial Fiberglass (050677) to reinforce the
Ball Stud Brackets (019082) as shown in the following illustration.

65. Using Scissors and a Tape Measure, cut two pieces of Biaxial Fiberglass (050677) to
the dimensions shown in the previous illustration.
66. Using Scissors, cut the 6mm slots shown in the previous illustration. Be careful not to
fray the Fiberglass.
67. Repeat the process to cut two additional sheets for the other Ball Stud Brackets
(019082).
68. Using a 13mm Combination Wrench, remove both Ball Studs from the Ball Stud
Brackets (019082).

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

15| Page

69. Using a flat piece of Cardboard as a mixing surface, mix a three inch diameter ball of
VE Putty (050674) with ten cubic centimeters of MEKP (050675).
70. Using a Disposable Mixing Tool, mix the VE Putty (050674) and MEKP (050675) until
the color is consistent.
71. Using Disposable Mixing Tool, apply the VE Putty (050674) around each Ball Stud
Bracket (019082) as shown in the following illustration. Spread the VE Putty to create
the smooth taper shown.

72. The Ball Stud Brackets (019082) should appear as shown in the following photograph
after the VE Putty (050674) is properly applied.

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

16| Page

73. Using a Plastic Container and a Disposable Mixing Tool, combine 16 Fluid Ounces of
Resin (002139) with 10 to 15 Cubic Centimeters of MEKP (050675).
74. Mix the combination thoroughly with a Disposable Mixing Tool.
75. Place the four cut sheets of Biaxial Fiberglass (050677) that were cut for the Ball Stud
Brackets (019082) onto a flat sheet of Cardboard.
76. Using a Paint Brush, apply the mixture to one of the smaller cut sheets.
77. Using a Paint Brush, saturate the sheet.
78. When the sheet is saturated, flip it over and saturate the other side.
79. When the sheet is saturated, place it over one of the Ball Stud Brackets (019082) as
shown by Ply 1 in the following illustration.

80. Using a Gloved Hand or a Paint Roller, smooth out any wrinkles and air bubbles.
81. Repeat the process to wet out and apply the remaining three sheets to the Ball Stud
Brackets (019082). Smooth each sheet with a Gloved Hand or Paint Roller.
82. Place the four cut sheets of Biaxial Fiberglass (050677) that were cut for the Hinge
Stud Plates (021156) onto a flat sheet of Cardboard.

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

17| Page

83. Add additional Resin (002139) and MEKP (050675) as needed to have enough
mixture to wet out the sheets that were cut for the Hinge Stud Plates (021156). Add
about 7 to 8 cubic centimeters per each 8 ounces of Resin.
84. Using Duct Tape, cover the Studs on the Hinge Stud Plates (021156) to prevent
corrosion from the Resin.
85. Beginning with one of the smaller sheets, saturate it with the mixture until both sides
are saturated.
86. Apply the sheet to one of the Hinge Stud Plates (021156) as shown in the following
illustration.

87. Repeat the process to wet out and apply the remaining sheets to both Hinge Stud
Plates (021156). Smooth each sheet with a Gloved Hand or Paint Roller as it is
applied.
88. The Smooth each sheet with a Gloved Hand or Paint Roller

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

18| Page

89. The Hinge Stud Plates (021156) should appear as shown in the following photograph.

90. Allow the Resin to cure until it is dry to the touch. The time will vary depending on heat
and humidity.
91. Remove the Duct Tape from the studs.
92. The Wet Layup Process is complete.
Trunk Panel Replacement:
93. Using a Jack Stand or other approved Lifting Device, support the Trunk Panel and position it
so that it can be reattached to the bus.
94. Using a 13mm Ratchet/Socket, replace the Locknuts that secure both Hinges to the Hinge
Brackets shown circled in red below.

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

19| Page

95. Reinstall the Gas Struts and secure them with their Retaining Clips.

Retaining Clip

96. Reconnect the wiring using the notes or photographs that were made when the wiring was
disconnected.
97. Using a 10mm Ratchet/Socket, secure the wiring to the Rotolocs in the same manner that it
was originally installed.
98. Close and latch the Trunk Panel.
99. Observe the gaps between the aft wrap and the Trunk Panel. They should be even as shown
in the following photograph. Adjust the Trunk Panel as necessary to even the gaps around
the Panel.

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

20| Page

100. Once the gaps are even, the Hinge Stud Plates (021156) locknuts may be torqued.
101. Using a Calibrated Torque Wrench with a 13mm Socket, torque the Locknuts to 14

foot pounds.

102. Using Orange Torque stripe paint, mark the properly torqued fasteners.
103. Remove the Lockout/Tagout device and power on the bus.
104. Return the bus to service after ensuring that all the rear trunk lights are functional.

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

21| Page