P03-271

Procedure 03-271
Tail Pipe Skid Plate Bracket Rework
Description:
This procedure outlines the steps to replace the welded bracket with the bolted-on brackets for
the tailpipe skid plate.
This procedure applies to J4500 coaches of MY 2018/19 within the VIN range: 68801-69485
and D45CRT coaches of MY 2019 within the VIN range 81000-81027.
Read this entire procedure before beginning work.
Use Safe Shop Practices at All Times.
To avoid personal injury:
a. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and
protective gloves are required for working with DEF Fluid.
b. Turn the main battery disconnect switch to the OFF position.
c. Ensure that both the front and the rear wheels are chocked.
d. Positioning the ENGINE RUN and ENGINE START switches on the engine
compartment remote control box to the OFF position.
e. Allow enough time for components to cool down prior to working in the engine
compartment.
1 | 9 Pages
Procedure 03-271
1.0
Material requirements:
ITEM
1
2
3
4
5
6
2.0
PART NO
T03-3076
T03-3077
T19-1170
T19-1171
19-2-63
T19-1172
QTY
1
1
4
4
4
4
U/M
EA
EA
EA
EA
EA
EA
DESCRIPTION
Bracket- Skid Plate, RH
Bracket- Skid Plate, LH
Bolt- Hex, 3/8-16, 3.25LG, SST
Nut- Hex, 3/8-16, SST
Washer-Flat, 3/8 ID, SST
Washer- LK, 3/8ID, SST
Special Tools:
No special tools required.
3.0
Remove the existing skid plate brackets:
Loosen the 6 bolts securing the rear bumper to the coach.
Loosen the 3
bolts on
driver side
Loosen the 3
bolts on
curbside
Remove and save the 2 bolts securing the rear bumper to the coach frame in the engine
access door compartment.
Remove and save
the 2 bolts in the
engine access
door compartment
2 | 9 Pages
Procedure 03-271
Remove and save the 2 bolts securing the rear bumper to the coach frame in the radiator
compartment.
Remove and
save the 2 bolts
in the radiator
compartment
Remove and save the bumper.
Remove and save the two nuts on the U-bolt securing the upper proheat exhaust pipe to
the lower proheat exhaust pipe. Save the clamp and U-bolt.
Upper proheat
exhaust pipe
U-bolt
Lower proheat
exhaust pipe
Remove and save the nut securing the lower proheat exhaust pipe to the bracket on the
coach. Slide-out the lower proheat exhaust pipe and save it.
Remove and
save the nut
3 | 9 Pages
Procedure 03-271
Remove and save the bolt securing the outboard skid plate bracket and skid plate.
Remove and
save the bolt
Grind the weld on the outboard skid plate bracket. Discard the bracket.
Grind the weld
Install the new LH skid plate bracket, MCI P/N: T03-3077, using the hardware removed
in the previous step.
Existing hardware
4 | 9 Pages
Procedure 03-271
With the holes on the new bracket as template drill pilot holes in the frame using a 1/4”
drill bit.
Drill pilot holes
Match drill the holes in the bracket using a 25/64 drill bit.
Drill 3/8” holes
Using the 3/8-16 bolt (MCI P/N: T19-1170, 3/8-16 nut (MCI P/N: T19-1171), 3/8 washer
(MCI P/N: 19-2-63), and 3/8 lock washer (MCI P/N: T19-1172) secure the LH skid plate
bracket to the coach frame. Torque the bolts to 20 Ft-Lbs.
3/8-16 bolts
5 | 9 Pages
Procedure 03-271
Remove and save the bolt securing the inboard skid plate bracket and skid plate.
Remove and
save the bolt
Grind the weld on the inboard skid plate bracket. Discard the bracket.
Grind the weld
Install the new RH skid plate bracket, MCI P/N: T03-3076, using the hardware removed
in the previous step.
Existing hardware
6 | 9 Pages
Procedure 03-271
With the holes on the new bracket as template drill pilot holes in the frame using a 1/4”
drill bit.
Drill pilot holes
Match drill the holes in the bracket using a 25/64 drill bit.
Match 3/8” holes
Using the 3/8-16 bolt (MCI P/N: T19-1170, 3/8-16 nut (MCI P/N: T19-1171), 3/8 washer
(MCI P/N: 19-2-63), and 3/8 lock washer (MCI P/N: T19-1172) secure the RH skid plate
bracket to the coach frame. Torque the bolts to 20 Ft-Lbs.
3/8-16 nuts
3/8 washer and
lock washer
7 | 9 Pages
Procedure 03-271
Torque the bolts securing skid plate brackets and skid plate to 33-37 Ft-Lbs.
Torque the bolts
to 33-37Ft-Lbs
Slide the lower upper exhaust pipe in the lower proheat exhaust pipe and secure them
with the existing clamp, U bolt, and nuts.
Clamp, U-bolt
and nuts
Secure the lower proheat exhaust pipe to the bracket on the coach using the existing nut.
Existing hardware
8 | 9 Pages
Procedure 03-271
Install the bumper to the rear frame of the coach and tighten the 6 existing bolts to 65-75
Ft-Lbs.
Location of the
3 bolts on
driver side
Location of the
3 bolts on
curbside
Secure the bumper to the coach frame in the engine access door compartment using the
existing bolts removed in Step2 and torque them to 18-22 Ft-Lbs.
Location of the 2
bolts in the engine
access door
compartment
Secure the bumper to the coach frame in the radiator compartment using the existing
bolts removed in Step3 and torque them to 18-22 Ft-Lbs.
Location of the
2 bolts in the
radiator
compartment
End of the procedure
9 | 9 Pages