SB 445

Service Bulletin No. 445
MODEL
TYPE
J4500
SECTION/GROUP
Field Change Program
7-Electrical
DATE
Mar. 24, 2017
SUBJECT
TRANSMISSION HARNESS ROUTING
CONDITIONS
MCI is informing owners of the J4500 model coaches listed in this bulletin that MCI Procedure
7-135 must be implemented in conjunction with FCP Service Bulletin 445.
Upon completion of the outlined retrofit steps in FCP Service Bulletin 445, customers are
instructed to contact the MCI Fleet Support Technical Center at 1-800-241-2947 to schedule an
appointment to have the specialized trained retrofit outlined in MCI Procedure 7-135 performed
on the coach.
The transmission harness and connector retrofit is NOT complete, and may be subject to water
migration into the transmission connector and harness, until both the FCP Service Bulletin 445
and MCI Procedure 7-135 have been performed.
Customer Complaint:
Motor Coach Industries ("MCI") has become aware that the J4500 series coaches listed in this bulletin may
experience water migration into the transmission connector and harness. In addition, the potential may exist
whereas the transmission interface harness wire loom may wear due to stress or movement at the point of
existing p-clamps or tyraps.
Damage to the transmission interface harness wiring may result in transmission codes, the PBSS ( pushbutton
shift selector ) not shifting, or transmission failure.
Cause:
Transmission harness routing.
Corrective Action:
As a result, MCI strongly urges owners of the MY2013, MY 2014, MY 2015, MY 2016 and MY2017 J4500 model
coaches listed in this bulletin to implement the steps in this procedure as soon as possible.
66554
66648 to 67895
67897 to 67967
67969
67971 to 67975
67977 to 67980
67982 to 67991
67993 to 68046
68049 to 68058
68060 to 68065
68072 to 68080
Service Bulletin No. 445
Date Mar. 24, 2017
Page 2
Parts
Qty.
New P/N
Description
1
26-07-0125
Kit, Transmission Harness Routing
Kit Contents are:
3
07-08-9052
Bracket, Transmission Harness
1
13-11-1387
Bracket, Transmission Bracket
2
07-08-4525
Tie Base, Panduit, TMEH-S10-C100
3
07-08-4526
Tie Base, Panduit, TM3S8-C100
2
07-08-4527
Cable Tie, Heavy Duty, 9 inch
2
07-08-4535
Wrap, Heavy Duty, Bl., 3 inch
2
19-02-6035
DIN9021B, A2/M5
3
19-1-586
Screw, #8-32 x 0.75, Cross, SST
2
19-1-825
Capscrew, Hex, 10-24 x 7/8
3
19-11-1011
Tyrap, Cable, Heavy Duty, 8-4
3
19-2-19
Washer, #8
3
19-2-73
Washer, Lock, #8, Steel
3
19-3-111
Nut, Hex, #8-32, Stainless Steel
2
19-3-228
Nut, Hex, w/Washer, #10-24 UNC
4
19-11-1845
Plug, Cavity
1
19-11-3078
Cable, Double Loop
1
19-01-1536
Capscrew, 1/2-13 x 1.50
1
19-03-0755
a/r
Nut, Flg, 1/2 -13
Loctite, 242
Service Procedure:
Read this entire procedure before beginning work.
Use Safe Shop Practices At All Times.
If the steps in this procedure are performed over a pit, chock the tires. Position the ENGINE RUN
and ENGINE START switches on the engine compartment remote control box to the OFF
position. Allow enough time for components to cool down.
If the steps in this procedure are performed with the coach on a lift, dump the air from the tag
axle suspension and raise coach to desired height. Position safety stands underneath the coach
in only the specified locations shown in Section 3F in the MCI J4500 Maintenance Manual ( as
shown in Figure 1 of this document ). Support the tag axle.
Ensure that the coach is securely supported before attempting work underneath the coach.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 3
1. Drive the coach over a pit, or use a lift to access the transmission harness.
2. Turn the main battery disconnect switch to the OFF position.
DO NOT place safety stands in any other location than shown in Figure 1 and Section 3F in the
MCI J4500 Maintenance Manual.
Figure 1. J4500 coach hoisting and safety stands location.
Figure 1 Description
Item
S
Safety Stand ( Primary locations )
J
Jacking Point
H
Hoisting Point
Service Bulletin No. 445
Date Mar. 24, 2017
Page 4
3. Locate the transmission harness connector, behind the roadside, tag axle wheel ( refer to Figure 2 ).
Figure 2. Transmission harness routing.
Visually inspect the transmission harness for:
•
•
•
Corrosion buildup on the internal pins of the transmission harness connector,
Chafing or damage to wire(s) at intersection points with p-clams or tyraps,
Stress on the interface connector.
.
If any of the above are present upon visible inspection, contact the MCI Fleet Support
Technical Center at 1-800-241-2947 for further information.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 5
If the coach is equipped with an Optional engine bay snow pan assembly, remove and retain the
six ( 6 ) capscrews and fender washers from the assembly. Carefully support the weight and
allow the assembly to swivel downwards and hang, supported on the assembly hinge as shown
in Figure 3.
If the coach is NOT equipped with an Optional engine bay snow pan assembly, proceed to Step
4.
3
2
1
Figure 3. Optional engine bay snow pan.
Figure 3 Description
Item
1
Optional engine bay snow pan assembly
2
Mounting hardware, quantity of six (6). Ref. capscrew p/n is 19-1-22, fender washer p/n is 19-2-119.
3
Nut weld, double tab, quantity of six (6)
Service Bulletin No. 445
Date Mar. 24, 2017
Page 6
4. At the forward section of the transmission, locate the transmission harness connector shown in Figure 4.
5. Using a 8 mm socket, loosen the mounting screw from the face of the transmission harness connector.
Carefully pull to disconnect the transmission harness connector ( refer to Figure 5 ).
Figure 4. Transmission harness connector location.
Figure 5. Transmission harness connector removed from the interface port.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 7
6. Visually inspect the transmission harness connector and the transmission interface port for corrosion
buildup on the internal pins ( refer to Figures 6 and 7 )
If upon visible inspection there is corrosion buildup on the internal pins as shown in Figures 6
and 7, contact the MCI Fleet Support Technical Center at 1-800-241-2947 for further information.
Figure 6. Evidence of corrosion on the transmission harness connector pins.
Figure 7. Evidence of corrosion on the transmission interface port.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 8
7. Locate the existing p-clamps shown as Item 1 in Figure 8.
8. Remove and discard the eight (8) existing p-clamps shown in Figure 8, as well as the p-clamps on the
dipstick.
1
1
1
1
3
1
2
Figure 8. Removal of p-clamps from transmission.
Item
Figure 8 Description
1
Remove and discard existing eight (8) p-clamps
2
Front bracket location
3
Rear bracket location
Service Bulletin No. 445
Date Mar. 24, 2017
Page 9
9. Visually inspect the transmission harness loom at the intersection point of the removed p-clamps. Open the
loom at the intersection point of the removed p-clamps and inspect the wrap, wire harness and individual
wires for damage ( refer to Figure 9 ).
If upon visible inspection there is damage or corrosion to the wire(s), contact the MCI
Fleet Support Technical Center at 1-800-241-2947 for further information.
Figure 9. Damaged wire in transmission harness.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 10
If the coach is equipped with an Optional engine bay snow pan assembly, proceed to Step 13 as
the existing bracket will be utilized in this retrofit.
If the coach is NOT equipped with an Optional engine bay snow pan assembly, proceed to Step
10.
10. Locate the existing front bracket shown as Item 2 in Figure 8.
11. Remove and discard the existing p-clamp and front bracket. Retain the mounting bolt to be used at a later
step in this procedure.
12. Using the existing mounting bolt from Step 11 and the new front bracket, p/n 07-08-9052, secure to the
transmission finger tight.
13. Orient the front bracket to a 30 degree angle, as shown in Figure 10. Tighten to secure at designated angle.
Torque to 74-89 ft-lbs.
14. Orient and install the new tie base, p/n 07-08-4526, using screw, p/n 19-1-586, nut, p/n 19-3-111, spring
washer, p/n 19-2-73 and washer, p/n 19-2-19.
1
2
Figure 10. Reference photo of front bracket at 30 degree angle and tie base.
Item
Figure 10 Description
1
Front bracket, p/n 07-08-9052
2
Orient and secure front bracket at a 30 degree angle
Service Bulletin No. 445
Date Mar. 24, 2017
Page 11
15. .Locate the existing rear bracket shown as Item 3 in Figure 8.
16. Remove and discard the existing p-clamp from the existing rear bracket.
17. Orient the rear bracket to a 30 degree angle, as shown in Figure 11. Tighten to secure at designated angle.
Torque to 74-89 ft-lbs.
18. Orient and install the new tie base, p/n 07-08-4526, using screw, p/n 19-1-586, nut, p/n 19-3-111, spring
washer, p/n 19-2-73 and washer, p/n 19-2-19.
1
2
Figure 11. Reference photo of front bracket at 30 degree angle and tie base.
Item
Figure 11 Description
1
Existing rear bracket
2
Orient and secure bracket at a 30 degree angle
Service Bulletin No. 445
Date Mar. 24, 2017
Page 12
4
1
2
4
3
Figure 12. Retrofit location guide.
Item
Figure 12 Description
1
Forward cooling bracket retrofit location, refer to Step 19
2
Rearward cooling bracket retrofit mounting hole location, refer to Step 22
3
Dipstick bracket retrofit mounting hole location, refer to Step 25
4
P-clamps to be removed and discarded
Service Bulletin No. 445
Date Mar. 24, 2017
Page 13
19. Locate the forward cooling bracket shown in Figure 13.
20. Remove and retain the existing bracket, screw and nut shown in Figure 13.
Figure 13. Existing forward cooling bracket.
21. Orient and install the existing bracket, screw and nut with the new bracket, p/n 07-08-9052, tie base, p/n 0708-4525, screw, p/n 19-1-825, washer, p/n 19-02-6035 and nut, p/n 19-3-228 as shown in Figure 14.
Tighten to secure.
Figure 14. Forward cooling bracket and tie base.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 14
22. Locate the mounting hole shown as Item 2 in Figure 12 as well as Figure 15.
Figure 15. Rear cooling bracket mounting location.
23. On a workbench, assemble the rear cooling bracket assembly using bracket, p/n 13-11-1387, tie base, p/n
07-08-4525, screw, p/n 19-1-825, washer, p/n 19-02-6035 and nut, p/n 19-3-228 as shown in Figure 16.
The bracket assembly must be pushed as far inboard towards the transmission as possible to
achieve a 0.50 inch clearance between the transmission harness routing and the dipstick.
24. Apply Loctite 242 to the threads of screw, p/n 19-01-1536. Orient the bracket assembly with screw, p/n 1901-1536 and nut, 19-03-0755 as shown in Figure 16. Push the bracket assembly as far inboard as the hole
will allow and tighten to secure.
Figure 16. Push the bracket assembly as far inboard as possible to achieve clearance.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 15
25. On a workbench, assemble the dipstick bracket assembly using bracket, p/n 07-08-9025, tie base, p/n 0708-4526, screw, p/n 19-1-586, lock washer, p/n 19-2-73, washer, p/n 19-2-19 and nut, p/n 19-3-111 as
shown in Figure 17.
26. Using the existing dipstick screw, mount the dipstick bracket assembly as shown in Figure 17.
Figure 17. Dipstick bracket and tie base.
27. Remove and discard the three ( 3 ) upper dipstick p-clamps shown as Item 4 / Figure 12.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 16
Refer to Figure 18 and Step 28 for orientation and routing of the transmission harness.
1
2
3
4
5
Figure 18.
Refer to Figures 19 to 21 for coaches equipped with an Optional severe duty package protection
shield.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 17
1
2
Figure 19. Optional severe duty package protection shield.
Item
Figure 19 and 20 Description
1
Optional input / turbine speed sensor protection shield / Severe duty option
2
Use existing hole in protection shield to match drill a hole in the extra transmission harness bracket.
3
Mount transmission harness bracket and tie bases as shown in Figure 20
3
2
3
Figure 20. Bracket and tie base install on protection shield.
Service Bulletin No. 445
Date Mar. 24, 2017
Figure 21. Transmission harness routing on protection shield.
Page 18
Service Bulletin No. 445
Date Mar. 24, 2017
Page 19
To avoid damage to harness loom and wires, use caution when utilizing tyraps.
Only use enough controlled force to prevent the harness from movement without
crimping the loom wall.
A tyrap that is too loose or too tight will result in damage to the loom and wires.
28. Locate the front cooling bracket shown in Figure 22 and Item 1 in Figure 18. Orient and install the heavy
duty wrap, p/n 07-08-4535, over the transmission harness at the intersection area of the panduit tie base.
Using tyrap, p/n 07-08-4527, secure the transmission harness as shown in Figure 22.
Figure 22. Installation of heavy duty wrap over the transmission harness.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 20
29. Locate the rear cooling bracket shown in Figure 23 and Item 2 in Figure18. Orient and install the heavy duty
wrap, p/n 07-08-4535, over the transmission harness at the intersection area of the panduit tie base. Using
tyrap, p/n 07-08-4527, secure the transmission harness as shown in Figure 23.
Figure 23. Installation of heavy duty wrap over the transmission harness.
30. Follow the routing of the transmission harness rearwards to the intersection area of the coolant hoses.
Visually inspect for contact between the transmission harness and the hoses as shown in Figure 24.
Upon visual inspection, if the transmission harness is contacting the coolant hoses in the area
shown in Figure 24, proceed to Step 31.
Upon visual inspection, if the transmission harness is not contacting the coolant hoses in the
area shown in Figure 24, proceed to Step 32.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 21
Figure 24. Visual inspection area of contact.
31. Orient and install the double loop cable, p/n 19-11-3078, over the transmission harness and coolant hose as
shown in Figure 25, with the cable base positioned in the middle.
Figure 25. Double loop cable installed with base positioning.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 22
32. Locate the front and rear brackets shown in Figure 26 and Items 3 and 5 in Figure 18. Orient and install a
tyrap, p/n 19-11-1011, to secure the transmission harness as shown in Figure 24.
Figure 26. Front and rear brackets.
33. Locate the dipstick brackets shown in Figure 27 and Item 4 in Figure 18. Orient and install a tyrap, p/n 1911-1011, to secure the transmission harness as shown in Figure 27.
Figure 27. Dipstick bracket.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 23
34. Orient the transmission harness connector to the transmission interface port. Using a 8 mm socket and the
mounting screw, re-install the transmission harness connector. Torque to 20-24 in-lbs.
If the coach is equipped with an Optional engine bay snow pan assembly, carefully swivel the
assembly upwards and secure in position with the existing six ( 6 ) capscrews and fender
washers. Torque the capscrew to 18-22 ft-lbs.
In addition to MCI Service Bulletin FCP 445, MCI Procedure 7-135 must be performed to
prevent transmission failure due to water migration.
35. Contact the MCI Fleet Support Technical Center at 1-800-241-2947 for further retrofit information regarding
sealing the open harness connector cavities with plugs outlined in MCI Procedure 7-135.
Procedure Complete.
Service Bulletin No. 445
Date Mar. 24, 2017
Page 24
Mail or fax the completed limited warranty claim form and verification form to MCI’s warranty department, or photocopy and mail to:
MCI Fleet Support
Attn: Warranty Department
7001 Universal Coach Drive
Louisville, KY 40258
Fax Number 1-800-360-8886
to receive credit for the hours used to complete this task. Contact the MCI Fleet Support Technical Center at
1-800-241-2947 for any further information.
Field Change Program Conditions:
The parts required for this rework will be supplied without charge.
A labor allowance of 1.3 hours will be granted for this rework on affected J4500 coaches.
This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached “MCI Field
Change Program Verification Form” and a “Warranty Claim Form” as detailed in your Owner Warranty manual to
MCI’s Warranty department. A “MCI Field Change Program Verification Form” needs to be submitted for each VIN
affected. Photocopy the attached “MCI Field Change Program Verification Form” as required for the number of affected coaches in your fleet.
This program will end on October 20, 2017.
Motor Coach apologizes for any inconvenience resulting from this campaign, but urges you to implement this
change as soon as possible.
Sincerely,
Motor Coach Industries
MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION
CONTACT INFORMATION
CUSTOMER NAME:
____________________________________________________
(PLEASE PRINT
FCP INFORMATION – ONE FORM PER UNIT
FCP#: _________
Coach Model ___________
COACH SERIAL #:
(At least the last 5 digits)
Model Year _____________
DATE COMPLETED __
/ __ /__
MILEAGE:
IMPORTANT: TO RECEIVE CREDIT FOR ANY ALLOWABLE LABOR CHARGES, THIS VERIFICATION FORM
MUST BE RETURNED TO MCI UPON COMPLETION OF THE FCP.
SUBMITTED BY: (Please Print)
________________________________________________________________
DATE
__ / __ /__
TITLE: (Please Print) ____________________________________________
SIGNATURE:
________________________________________________________________
COMMENTS:
F A X T O : 800-360-8886
MAILING ADDRESS:
MOTOR COACH INDUSTRIES
ATTN: WARRANTY DEPT.
7001 UNIVERSAL COACH DRIVE
LOUISVILLE, KY 40258
MCI part # 03-15-7738C