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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
01-29-03 508 The entire dashboard is loose. Installed a 24" piece of aluminum angle at the base of the dast and two 3" pieces of strap at the instrument panel. 1.0 1.0
02-24-03 876 The dash and instrument cluster are loose. 4" x 31" anchor strip installed and fasteners replaced with new. 4.0 0.5
03-07-03 876 The front, 3 piece bumper mount is loose causing the front body cap to crack. One piece C-Channel installed over 3 piece mounting plates to stiffen assembly. 1.5 1.5
03-13-03 1012 The air line to the driver's seat isbroken. Air line rerouted and spliced. 1.0 1.0
04-03-03 1498 The front body cap is cracked. Cracks repaired with fiberglass. 2.0 2.0
04-03-03 1498 The dash board is loose. Aluminum angle added to secure dash and instrument cluster. 296.0 6.0
04-03-03 1498 The grill is loose, fasteners are missing. Missing fasteners replaced. 0.25 0.25
04-03-03 1498 The front bumper is loose. Mounting bolt holes increased from 5/8" to 3/4" 0.5 0.5
04-15-03 2514 The air line to the driver's seat is leaking. Air line to the driver's seat replaced. 3.0 0.5
06-11-03 3343 The driver's side windshield fell out. Removed right side windshield. Replaced gasket and reinstalled both windshields. 182.0 2.0
11-12-03 4220 The right side body panel under the rear door is loose. Broken rivets replaced. 0.5 0.5
11-24-03 5549 The left side lower body panel is loose. Broken rivets replaced. 1.0 1.0
11-24-03 5549 The right side bonded roof seam is separating. Seam secured with rivets. 1.0 1.0
11-26-03 5715 The front body cap corners are cracking. Cracks repaired with 6"x12" fiberglass matting. 9 1/2" x 82" piece of plywood installed under existing flak board under structure for support. 48.0 4.0
03-30-04 8998 The body frame structure has 19 cracks throughout the structure. All cracks welded/repaired. 32.0 3.0
04-27-04 10200 The second window on the right side is falling out. Replaced fasteners in window frame. 1.0 1.0
04-27-04 10200 The rear door is loose. The upper hinge pin is broken. Upper hinge pin replaced. 1.0 1.0
02-17-04 6732 Numerous body cross members are cracked or broken. Added crosds members and partial cross members depending on free space available between the body and frame rails. Two full length cross members added approximatley 24" in front of the rear axle. Four angle gussets inserted into the cross members over laying were broken. Ten partial cross members (24" to 36" in length) were added to broken cross members. All repairs welded. Broken door frame; steel plates and gussets added where needed. Handicap entrance; gussets welded to each lower corner. 1104.0 24.0
02-23-04 7047 Air leak in rear service brake air line. Failed air line replaced. 8.0 0.5
03-05-04 7864 The front clearance lights are inoperative. Failed circuit breaker replaced and repaired shorted wire to the shift indicator light. 1.0 1.0
03-17-04 7916 The front heater will not function. Replaced blown fuse, cause not found. 8.0 2.0
04-28-04 10430 Bus caught on fire at the durability track due to an electrical failure in the panel beside the driver's seat. The electrical panel beside the driver's seat caught fire. Fire extinguished. Manufacturer notified. 0.0 0.0
05-06-04 10493 Repair damage due to fire on 4/28/04 Manufacturer's rep. replaced electrical components and repaired damage in electrical panel beside the driver's seat. 214.0 6.0
01-20-03 319 The air cleaner came apart. Air cleaner reassembled. 1.0 0.25
01-29-03 508 The crankcase dip stick has broken and fallen into the pan. Oil pan removed, broken dip stick recovered. New dip stick ordered. 152.0 1.0
04-09-03 1610 Speedo head and gauges not functioning. Installed new speedo head and gauge package. 9.0 2.0
04-09-03 1610 The coolant line from the recovery tank to the water jacket is broken. 3/8" x 36" coolant line replaced. 4.0 1.0
06-03-03 3152 The engine is loosing throttle. The "Check Engine and Check Trans" lights are on. The left side A/C compressor (not in use) lost it's mounting bolts and is hitting the upper ECU connector. Compressor removed and connector repaired. 15.0 2.0
11-07-03 4022 The right side A/C compressor belt came off. Drive pulley and compressor pulley realigned and belt replaced. 2.0 2.0
11-07-03 4022 Crankcase dip stick came out and hit cooling fan. Dip stick replaced and fan blades repaired. 32.0 1.0
11-11-03 4076 The coolant line to the thermostat housing is split and leaking. Split coolant line replaced. 4.0 1.0
02-23-04 7047 The upper radiator hose is leaking. Upper coolant line clamp tightened. 0.5 0.5
02-26-04 7240 Bus shut down while on durability track. Engine cranks but will not start. Trouble shooting found broken ground wire at the ECM. Broken ground wire repaired and the terminal replaced on the ground wire at the battery. 38.0 4.0
02-27-04 7407 The bottom radiator coolant line is leaking. Failed coolant line replaced. 6.0 1.5
03-23-04 8590 Bus shut down while on durability track. Engine cranks but will not start. Repaired relay pins and replaced relay that fell out of electrical panel. 8.0 1.0
03-24-04 8650 The coolant line to the surge tank is leaking. Leaking coolant line replaced. 1.0 1.0
04-07-04 9815 Numerous radiator fan blades are damaged. Damaged fan blades replaced. 1.0 1.0
04-27-04 10200 Engine cranks but will not start. Repaired open circuit to circuit 439 B (+12 volt to engine ECM). 32.0 2.0
04-27-04 10200 The transmission will not shift. "Check Trans" light is on. Speedo head replaced and failed resistor in J1939 circuit repaired. 2.0 2.0
03-15-04 7864 The cross member forward of the rear axle is cracked. Cross member replaced. 144.0 2.0
03-30-04 8998 The frame-to-body cross member on the right side behind the rear axle is broken. Broken cross member welded/repaired. 1.5 1.5
02-23-04 7047 The front passenger door will not function. Failed switch ordered. 0.5 0.5
03-30-04 8998 The handicap door fastener mounting holes are worn. Holes drilled and tapped. New fasteners installed. 0.25 0.25
03-07-03 876 The left front shock bracket and shock are broken. Left front shock and shock bracket replaced. 0.5 0.5
03-15-04 7864 The front sway bar is broken. Front sway bar replaced. 1.0 1.0
01-20-03 319 The upper steering column bracket is broken. Bracket welded/repaired. 8.0 2.0
01-29-03 508 The bracket for the steering wheel telescope cylinder is loose. Mounting screws replaced and bracket tack welded to the column. 2.0 1.0
02-24-03 876 The clevis in the steering column tilt adjustment is broken. Steering column replaced. 472.0 2.5
03-05-04 7864 The steering column is loose. 14" x 7" aluminum plate installed to secure steering column. 24.0 3.0
04-07-04 9815 The power steering pump has failed. Power steering pump replaced. 64.0 2.0