DTNA Solutions > Service Solutions » Thomas Built Bus >» SS 582773: EFX Shock Mount /Frame Rail Crack Repa...
SS 582773: EFX Shock Mount /Frame Rail Crack Repair S
Applicable Vehicles
Thomas Bus EFX
Symptoms
Aminor crack in the frame rail could appear around the shock mount on some buses.
Issue
There is a potential for a small crack to form on the frame rail around the shock mounting bracket on the front suspension of the EFX Transit
buses.
Solution
Aretrofit has been designed to replace the current shock mount bracket with a new design. This fix requires frame welding, as called out in the
workshop manuals, as well as additional holes to be added for the new brackets. step by step instructions for the process are attached to this
solution. Please follow instructions and safe practices when performing this repair.

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Thomas Bus EFX Shock Mount Retrofit
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[ITEM # | DESCRIPTION TBB PART # | DTNA PART #
BRKT-MOUNT, SHOCK, UPPER FRT, EFX 252338 TBBN252338 | 4
SCREW, CAP,HEX,1/2-13,GR8,ZNDI 61370644 | 23-11751-150| 8
WASHER-HRDN,0.53X1.06X.177,ZN 61370352 | 23-09114-003
| 4 |NUT-HEX,LKG,XLSIL,1/2-13 61370043 | 23-13833-108] 8 |
FIXTURE-HOLE DRILLING, EFX 252430 TBBN252430
TOOL AND MISCELLANEOUS
QUANTITY DESCRIPTION
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TBBN252430 — FIXTURE-HOLE DRILLING,EFX
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1. PREPARING FOR INSTALLATION (COMMON FOR LH AND RH RAIL)
4.1. PARK VEHICLE ON LEVEL GROUND AND ENGAGE PARKING BRAKE TO LOCK REAR WHEELS.
4.2. LIFT FRONT AXLE WITH A JACK AND SECURE IT WITH HEAVY-DUTY AXLE STANDS TO TAKE LOAD OFF THE SHOCK ABSORBER.
4.3. ENSURE STEERING IS CENTERED AND LOCK THE STEERING TO PREVENT MOVEMENT.
1.5. REMOVE & DISCARD SHOCK ABSORBER MOUNTING HARDWARE
ALONG WITH BACKING PLATE AND SHOCK MOUNTING BRACKET ON
BOTH SIDES. INSPECT FRAME AT SHOCK BRKT LOCATION FOR ANY
DAMAGE, IF DAMAGED REPAIR PER Saf-T-Liner C2 SCHOOL BUS
WORKSHOP MANUAL.
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1.4. LOOSEN LUG NUTS & SA icture 1.
REMOVE FRONTS WHEEL Z Preparation.
ASSEMBLY ON BOTH SIDES
FOR CLEAR ACCESS TO
SHOCK BRACKETS
4.6. REMOVE SHOCK ABSORBERS FROM BOTH SIDES AND KEEP ASIDE FOR LATER INSTALLATION.

2. FIXTURE INSTALLATION (LH RAIL)
14. TO POSITION FIXTURE:
1. POSITION THE FIXTURE ON LH FRAME BY INSERTING PINS IN CURRENT SHOCK ABSORBER BRACKET MOUNTING HOLES.
2. TO SECURE FIXTURE:
1. USE DUCT TAPE TO SECURE THE FIXTURE ON THE RAIL, DO NOT COVER ANY HOLE.
CURRENT SHOCK (5) FIXTURE
ABSORBER BRACKET
MOUNTING HOLES N
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Picture 1.2
Fixture positioned on LH Rail.

2. FIXTURE INSTALLATION (LH RAIL) A TORQUE TO TARGET 55 FT-LBS, RANGE: 44-66 FT-LBS .
3. MARK THE PILOT (TO BE DRILLED) HOLES:

1. ONCE THE FIXTURE IS IN PLACE, MARK HOLES WITH A PAINT MARKER AND PUNCH CENTER FOR DRILL LOCATION.
4. DRILLING PROCESS:

1. ENSURE ALL HARNESS AND HOSES ARE MOVED FROM DRILL LOCATION PRIOR DRILLING HOLES.

2. DRILL ALL MARKED HOLES USING A 0.562” (9/16”) DRILL BIT.

3. REMOVE ALL SHAVINGS AFTER DRILLING WITH A BRUSH.
5. NEW BRACKET:

1. INSTALL NEW BRACKET AND THE SCREWS ON EACH HOLE PER BOM MENTIONED IN SHEET 1.

2. INSTALL SHOCK ABSORBERS AND WHEEL ASSEMBLY.

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2. FIXTURE INSTALLATION (RH RAIL)
1. TO FILL UN-USED HOLE:
1. FILL THE MARKED HOLE WITH WELD MATERIAL BEFORE POSITIONING FIXTURE.
CURRENT SHOCK ABSORBER
BRACKET MOUNTING HOLES
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UN-USED HOLE C)
TO BE FILLED t L) C)
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Picture 1.3
Filling un-used hole on RH Rail.

2. FIXTURE INSTALLATION (RH RAIL)
2. TO POSITION FIXTURE:
1. POSITION THE FIXTURE ON RH FRAME BY INSERTING PINS INCURRENT SHOCK ABSORBER BRACKET MOUNTING HOLES.
3. TO SECURE FIXTURE:
1. USE DUCT TAPE TO SECURE THE FIXTURE ON THE RAIL, DO NOT COVER ANY HOLE.
(5)) FIXTURE
CURRENT SHOCK ABSORBER
BRACKET MOUNTING HOLES N
OU Cee rn RH RAIL
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NEW HOLE 4 q
POSITIONS XS
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Picture 1.4
Fixture positioned on RH Rail.

2. FIXTURE INSTALLATION (RH RAIL) Z\ torque TO TARGET 55 FT-LBS, RANGE: 44-66 FT-LBS .
4. MARK THE PILOT (TO BE DRILLED) HOLES:
1. ONCE THE FIXTURE IS IN PLACE, MARK HOLES WITH A PAINT MARKER AND PUNCH CENTER FOR DRILL LOCATION.
5. DRILLING PROCESS:
1. ENSURE ALL HARNESS AND HOSES ARE MOVED FROM DRILL LOCATION PRIOR DRILLING HOLES.
2. DRILL ALL MARKED HOLES USING A 0.562” (9/16”) DRILL BIT.
3. REMOVE ALL SHAVINGS AFTER DRILLING WITH A BRUSH.
6. NEW BRACKET: 2x
1. INSTALL NEW BRACKET AND THE SCREWS ON EACH HOLE PER BOM MENTIONED IN SHEET 1.
2. INSTALL SHOCK ABSORBERS AND WHEEL ASSEMBLY.
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*Information on the next three pages is copied directly from C2 Workshop Manual.
REPAIRING THE CRACKS IN FRAME RAIL Please use as a reference
+ Before performing any electric welding on a vehicle, read and understand the welding precautions in Subject 110.
+ Disconnect the battery power and ground cables and any electronic control units (ECUs) installed on the vehicle.
+ Electric currents produced during electric welding can damage various electrical components on the vehicle, such as alternator diodes and
ECUs.
+ Freightliner vehicle components that typically use ECUs include electronic engine, electronic automatic transmission, and ABS (antilock
braking system).
+ For any ECU with a battery power harness, disconnect its ground terminal from the chassis ground, and disconnect its power terminal from
the battery positive post, or disconnect the main connection at the ECU.
1. Drill a 1/8-inch (3-mm) diameter hole at each end of the crack to prevent further spreading of the crack. See Fig. 1.
2. Vee out the crack to a depth of two thirds of the stock thickness. See Fig. 2.
NOTE: If it will not be possible to grind both sides of the frame rail, then grind the vee groove on one side to the full depth of the stock thickness. See
Fig. 3.
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09/19/2003 Ve #3100120 os14/95 1310013a
1. 1/8-inch (3-mm) Diameter Hole A. Frame Rail Thickness .
2. Crack B. Grind a vee groove two thirds the depth of the stock Series: 7 Bie
thickness. A. Frame Rail Thickness
Fig. 1, Preventing Cracks from Spreading 4. Crack 1. Vee Groove (Full Depth)
Fig. 2, Cross-Section View Fig. 3, Full Depth Groove

REPAIRING THE CRACKS IN FRAME RAIL
3. Clamp a copper or aluminum bar on the opposite side of the groove. The bar will act as a "chill* strip, keeping the heat from spreading to the
surrounding area of the frame rail. See Fig. 4. Deposit the weld material using the applicable welding method described in this section.
4. Grind the weld flush with the frame rail. See Fig. 5.
5. Cut a deep enough vee groove on the opposite side of the frame rail to reach the weld metal. See Fig. 6.
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08/15/95 (3100174

08/14/95, 310015a a .
A. Fi Rail Thicki A. Frame Rail Thickness

tame all uc ness ea ERASE TeDDAGE B. Grind the vee groove deep enough to reach the
B. Clamp the "chill" strip on the opposite side of the A. Frame Rail Thickness weld
C. Deposit weld material, B. Grind the weld flush with the frame rail.

Fig. 6, Cross-Section View
4. Crack 1. Crack
Fig. 4, Using a Chill Strip Fig. 5, Weld Ground Flush

REPAIRING THE CRACKS IN FRAME RAIL
6. Clamp the "chill" strip on the opposite side of the groove. See Fig. 7. Weld the vee groove, as instructed above. Make full penetration of the
weld.
7. Grind the weld flush with the frame rail. See Fig. 8.
A— — A
B c
B
08/15/95 1310018
A. Frame Rail Thickness
B. Deposit weld material to penetrate the opposite 40/12/94 310019a
weld x -
C. Clamp the "chill" strip on the opposite side of A. Frame Rail Thickness . .
groove B. Grind the weld flush with the frame rail
Fig. 7, Second Weld Fig. 8, Second Weld Ground Flush