ITS61456 Service Bulletin/Repair Instructions

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.
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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
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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
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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
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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.
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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
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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

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