INSTRUCTION TO SERVICE
ITS61456

02/12/26

SECTION:

460-Windows

SUBJECT:

Realign windshield support plate

ISSUE:

Vertical stress crack on windshields

SUMMARY:

Rework windshield frame per this ITS

ITS61456
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
ITS61456

SAFETY PRECAUTIONS MUST BE FOLLOWED ACCORDING TO ACCEPTED INDUSTRY
STANDARDS AND LOCAL/PROPERTY REQUIREMENTS.

PROCEDURE:
1. Park bus on a flat surface and apply parking brake. Place wheel chocks underneath the front wheels.
2. Inspect windshields for vertical stress cracks. Depending on the location of the crack, proceed with the repairs
detailed below as applicable.

Example of a vertical stress
crack located on the LH (driver
side) windshield.

ITS61456

Page 2 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456
Repair if crack is on the curb side (RH) windshield
3. If windshield was recently replaced due to vertical stress crack, and the new windshield has no cracks now,
then the frame repair can be done from inside, without removing the windshield. Inspect side plate alignment
from outside: if the aft edges of the center and side plates are aligned then repair is required. Refer to Figure
1 below.

Inspect plate alignment
from this angle

The aft edges of the center and
side plates are aligned that
indicates that the small side plate
is not engaged correctly inside the
rubber seal. Repair is required.

Center support profile.

This is a correct alignment: the
small side plate is pushed
forward and the aft edges of this
and the center profile are not
aligned. No repair is required.

Example of an incorrect side plate
installation at the LH (streetside):
the forward edges of the center and
side plates must be aligned to
adequately support the windshield.

Figure 1: Side plate alignment inspection

ITS61456

Page 3 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456
4. Remove grab rail, bulkhead panel, defroster louvers and CS dash panel to get access to the windshield
support frame. Refer to Figure 2.

Figure 2: Remove interior components to get access to the windshield support frame
5. Drill the head of the mounting rivets of the plate out. Use a piece of cardboard to protect the windshield in
case the drill jerks or jumps. Refer to figure 3.

Figure 3: Drill out the head of the rivets

ITS61456

Page 4 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456
6. Punch the rivets into the structure.

Figure 4: Punch rivets into the structure
7. Remove the plate. Clean metal shavings from both the bus frame and plate. Refer to Figure 5.

Figure 5: Support plate is removed

ITS61456

Page 5 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456
8. If windshield was removed, then install new windshield into the rubber seal but don’t install lacing yet.
Windshield is required so the plate can be positioned correctly to match the curvature of the windshield.
9. Apply silicone spray or soapy water onto the plate, then push the plate into the horizontal groove of the seal
all the way forward. Secure plate to the structure with a clamp. Refer to Figure 6.

Lift the outer lip of the rubber seal and ensure
the plate is pushed all the way into the
horizontal groove of the rubber seal.

Horizontal groove of the rubber seal

Clamp
.

Push plate forward into the rubber seal.
Figure 6: Push plate forward, into the slot of the rubber seal
10. Drill top surface of the structural tube through the existing holes of the plate by using a #10 size (0.1935”) drill
bit.

ITS61456

Page 6 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456
11. Install 3/16” size SST rivets (PN 19-13-0333) through the holes. Refer to Figure 7.

Figure 7: Secure support plate with 3/16” size SST rivets
12. Install lacing to complete the windshield installation (if new windshield was installed).
13. Reinstall dash panel, bulkhead panel and grab rail.
Repair on the LH (driver side)
14. To rework the side support plate at the LH side, the windshield must be removed.
15. Drill out rivets, clean plate, apply soapy water on it and push it forward inside the horizontal groove of the
rubber seal as described before. See paragraphs 5-9.
16. Since the windshield had to be removed to get access to the side plate, the alignment of the side plate must
be done with more attention:
a.

Pull the rubber seal off from the joint area of the side plate and the center support profile. Refer to Figure
8.

Side support plate

ITS61456

Figure 8: Pull seal off from the joint area

Page 7 of 9

Center support
profile

02/12/2026

INSTRUCTION TO SERVICE
ITS61456

b.

Push the side plate forward and ensure that its forward edge is aligned with the center profile. Refer to
Figure 9.

Figure 9: Align inner corner of the side plate with the center profile
c.

Secure this inner corner of the side plate to the structure with a clamp.

d.

Push the outer corner of the side plate into the horizontal groove of the rubber seal. Ensure the inner
corner of the side plate is still aligned with the center profile.

17. Drill structure, install rivets as described before. Refer to paragraphs 10-11.
18. Ensure the joint area of the side plate and center profile are aligned and leveled. Use a file or grinding disc to
remove sharp edges and smoothen the joint area if required.
19. Reinstall rubber seal onto the joint area of the side plate and center profile. Ensure that the plate is fully
engaged into the horizontal groove of the rubber seal. Refer to the top photo at Figure 6.
20. Reinstall LH windshield.
21. Remove tools, debris and unused parts from the bus to return it to service condition.

ITS61456

Page 8 of 9

02/12/2026

INSTRUCTION TO SERVICE
ITS61456

LABOUR ESTIMATE
Number of
Technician(s)
1

Operation
1

Rework one support plate per this ITS

Hours
6

Labor Time
T X HR
6

PARTS REQUIRED
Item

Part Number

Description

1

19-13-0333

RIVET 3/16 DIA , SST

Qty.
per
Coach
9

Units

Qty.

Units

Notes

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

1

NA

ITS61456

Description

Notes

Windshield lacing tool, drill, rivet gun

Page 9 of 9

02/12/2026