Service Bulletin No. 2883

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1 Service Bulletin No MODEL TYPE SECTION/GROUP DATE SUBJECT 102B3/102C3/102D/102DL/ D4000/D4500/MC12 Series Coaches Service Information TRW TILT STEERING COLUMN 11--Steering System May 4, 2004 CONDITIONS Parts may be purchased from MCI Service Parts, Louisville, Kentucky or from MCI ServiceParts,Newcastle,Ontario. Description: MCI is informing our customers that TRW has released a Service Bulletin regarding the correct method for inspecting the steering column tilt lock used on MCI 102B3, 102C3, D and MC 12 series coaches. Service Procedure: General notes Read this entire procedure before beginning work. UseSafeShopPracticesAtAllTimes. 1. Turn the main battery disconnect switch to the OFF position. Chock both sides of the tires. REFER TO MANUAL Refer to Section 11B / Steering Wheel and Column, in the MCI D Series Maintenance Manual, in conjunction with this procedure. 2. Push the tilt lock lever located on the LH side of the steering column outward ( Figure 1 ). Hold the steering wheel and push or pull to the middle of the tilt range. Release the lock lever. Figure 1. Tilt lock lever location on steering column. 3. Apply slight pressure to the steering wheel, ensuring that the tilt lock is fully engaged. Printed in Canada

2 Service Bulletin No DATE MAY 4, 2004 PAGE 2 4. Using lbs. of force, push the steering wheel towards and away from the driver s seat. NOTE Force applied to the steering wheel should not be an impact load. 5. If the steering column remains properly engaged with the lbs. of force applied, no further action is required. 6. If the steering column disengages or ratchets with the lbs. of force applied, the tilt lock mechanism requires cleaning as outlined in attached TRW Service Bulletin COL 103 ( Service Bulletin COL 103 distributed with permission of TRW ). NOTE A light---weight oil can be used in place of the dry lubricant, referenced in Step 9 of TRW Service Bulletin COL Repeat Step 4 after completing all of the outlined steps in TRW Service Bulletin COL 103. If the steering column remains properly engaged with the lbs. of force applied after cleaning, no further action is required. 8. If the steering column disengages or ratchets after cleaning, it will have to be repaired or replaced using the service replacement part numbers shown in Figure 2. 11L L L L L L L L L L L L L L A L L L Procedure complete. Printed in Canada Figure 2.

TRW Automotive Steering & Suspension Systems Service Bulletin #COL-103 Tilt/Telescope Column Tilt Mechanism Cleaning Procedure for columns TC34017 - TC34025, TC34027-TC34030, TC34032-TC34035,

Remove handle This TRW Commercial Steering Division service bulletin has been written to help you repair commercial vehicles more efficiently.

You should not try to diagnose or repair steering problems unless you have been trained, and have the right equipment, tools and know-how to perform the work correctly and safely. 1.

3 TRW Automotive Steering & Suspension Systems Service Bulletin #COL-103 Tilt/Telescope Column Tilt Mechanism Cleaning Procedure for columns TC TC34025, TC34027-TC34030, TC34032-TC34035, TC34037, TC34040 & TC34041 Released July, 1992 Electronic Version April, 1998 Do not remove column from vehicle. Photos taken on bench for clarity only. Remove handle This TRW Commercial Steering Division service bulletin has been written to help you repair commercial vehicles more efficiently. This bulletin should not replace your manuals; you should use them together. These materials are intended for use by properly trained, professional mechanics, NOT Doit-yourselfers. You should not try to diagnose or repair steering problems unless you have been trained, and have the right equipment, tools and know-how to perform the work correctly and safely. 1. Extend column to full telescope out, and raise column into full tilt up position to minimize spring loads. Remove tilt handle. Remove spring cover plate The enclosed springs will push the spring cover plate out; hold it tightly during this procedure. 2. Locate the tilt/telescope actuator housing and remove the spring cover plate screw. Remove the spring cover plate. Remove screws Enclosed are two (2) springs that will push the actuator housing away from the column housing. Hold it tightly while removing. 3. Remove the four (4) screws that hold the tilt/ telescope lever acutator housing to the tilt column.

Remove actuator housing, cam and pin assembly 4. Remove the actuator housing and tilt/telescope cam & pin assembly.

Study the location of the lock bar, wedge lock and disengaging plate prior to removal.

Lock Bar Disengaging Pin Remove plate, lock bar, wedge lock and springs 6. Remove the disengaging plate, lock bar, wedge lock and springs.

Carefully inspect the disengaging plate for broken, cracked or otherwise damaged tabs. Replace if damaged or broken.

4 Remove actuator housing, cam and pin assembly 4. Remove the actuator housing and tilt/telescope cam & pin assembly. Do not lose the two springs attached to the cam & pin assembly. Wedge Lock Study component positions 5. Study the location of the lock bar, wedge lock and disengaging plate prior to removal. These components will be installed in the same location later in the procedure. Lock Bar Disengaging Pin Remove plate, lock bar, wedge lock and springs 6. Remove the disengaging plate, lock bar, wedge lock and springs. Replace any component that is damaged or broken. Inspect disengaging plate tabs 7. Carefully inspect the disengaging plate for broken, cracked or otherwise damaged tabs. Replace if damaged or broken. Tabs Clean housing cavity and removed components 8. Remove all grease and dirt from the lock bar/wedge lock cavity in the main housing by wiping the cavity with a clean shop towel. Clean all components in a clean, petroleum-based solvent and air-blow them dry. Since they are flammable, be extremely careful when using any solvent. Even a small explosion or fire could cause injury or death.

Prepare for assembly 9. Apply dry lubricant to the cavity in the tilt column housing, the lock bar, wedge lock and the disengaging plate.

Engage the lock bar teeth with the support bracket teeth. Locating Pins Install wedge lock 11.

Assemble disengaging plate (with tabs out) onto the lock bar and wedge lock locating pins.

5 Prepare for assembly 9. Apply dry lubricant to the cavity in the tilt column housing, the lock bar, wedge lock and the disengaging plate. These components will be either silver or black. Install lock bar 10. Assemble lock bar into main housing with locating pin out. Engage the lock bar teeth with the support bracket teeth. Locating Pins Install wedge lock 11. Assemble wedge lock next to lock bar with tapered end toward the support bracket teeth and the locating pin out. Wedge Lock Install disengaging plate 12. Assemble disengaging plate (with tabs out) onto the lock bar and wedge lock locating pins. Lock Bar Disengaging Pin Actuator Housing Spring Bushing Assemble actuator cam assembly into actuator housing 13. Install the actuator cam and lock pin assembly, with springs, into actuator housing and bushing assembly. Make sure the actuator housing spring (large) goes into the bushing in the actuator housing. The anti-rattle spring should remain as shown. Anti-Rattle Spring

Lug Raised Tabs Cam Ears Install actuator housing assembly 14. Assemble the actuator housing assembly on the main housing.

Actuator cam ears must be assembled under the disengaging plate's raised tabs; and actuator housing alignment lugs must be engaged in main housing.

While holding actuator housing firmly down on main housing, tighten four self-tapping screws into the actuator housing and main housing.

Assemble lock bar spring on the end of the lock bar and wedge lock spring on the end of the wedge lock.

6 Lug Raised Tabs Cam Ears Install actuator housing assembly 14. Assemble the actuator housing assembly on the main housing. The lock pin must be inserted into the bushing in the main housing. Actuator cam ears must be assembled under the disengaging plate's raised tabs; and actuator housing alignment lugs must be engaged in main housing. The springs will push the actuator housing away from the column housing. Hold it tightly until screws are installed. Install screws 15. While holding actuator housing firmly down on main housing, tighten four self-tapping screws into the actuator housing and main housing. Torque screws to in. lbs. ( Nm) using a 5 16" hex socket. Install springs and spring cover plate 16. Assemble lock bar spring on the end of the lock bar and wedge lock spring on the end of the wedge lock. Hold spring cover plate firmly down over the ends of the two springs while turning self-tapping screw into actuator housing and bushing assembly. Torque screw to in. lbs. ( Nm) using a 5 16" hex socket. Reinstall tilt lever 17. Reinstall tilt lever. TRW Commercial Steering Division P.O. Box 60 Lafayette, IN Phone: Fax:

Steering. Table of Contents

Steering. Table of Contents Steering Table of Contents Sub-Headings Safety 2 Warnings 2 s 2 s 2 Introduction 2 Description of Service Manual 2 General Design 2 Removal of Steering Wheel and Column 2 Steering Column Removal 3 Steering