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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
07-29-08 3,069 The wiper switch is broken. Wiper switch replaced. 1.0 1.0
08-11-08 3,840 The air tank is broken from the mounts and leaking, Air tank replaced. 1.0 0.5
08-18-08 3,840 The rear sway bar bushings are worn. Rear sway bar bushings replaced. 1.0 1.0
08-27-08 3,955 The transmission bell housing is cracked. Axle removed for towing to repair shop. Transmission removed and cracked bell housing replaced by warranty dealer. Transmission reinstalled. 344.0 32.0
04-04-08 101 The rear wheels are hitting at the top of the wheel well. Mor-Ryde suspension 288.0 4.0
04-04-08 101 Located a CNG fuel leak at the union on the fuel supply line on the roof. Union tightened, leak stopped. 1.0 2.0
04-24-08 452 The right side sway bar bushing is missing on the rear sway bar. Bushing replaced. 40.0 2.0
04-25-08 452 The left rear Mor-Ryde carrier spring is broken. Replaced both carrier springs and swing arms. Note: swing arms have a modified angle. 20.0 6.0
04-29-08 548 The test bus is disabled on the highway. Engine cranks but will not start. Test bus towed to shop. Troubleshooting found the primary fuel regulator frozen up. Further trouble shooting showed insufficient cooling fluid flow to the regulator. Manufacturer is working on a solution. 8.0 6.0
05-05-08 556 The weld on the right side Mor-Ryde suspension tower is broken. Right side weld repaired and left side rewelded. 264.0 2.0
05-07-08 556 The right front engine mount bolt is broken. Radiator pack and alternator removed to access broken engine mount bolt. Engine mount bolt replaced. Radiator pack and alternator replaced. 4.0 8.0
05-12-08 556 Engine cranks--will not start. The fuel pressure regulator is frozen. Troubleshooting found the circulating pump inoperative--no coolant flowing through the regulator. Located circulating pump wiring and connected to ignition power. 32.0 4.0
05-23-08 663 The right front engine mount bracket has a broken bolt. Engine mount dissassembled and broken bolt removed. Engine mount bracket reassembled with new bolt and three other mount bolts replaced. 7.0 14.0
06-06-08 663 The rear axle sway bar bushings are worn. Rear axle bushings replaced. 1.0 2.0
06-10-08 852 The right side engine mount bracket bolts are loose. Both sides (4) engine mount bolts replaced. 32.0 2.0
06-16-08 1,022 The right side bushing is missing on the rear sway bar. Bushing replaced. 14.0 1.0
06-16-08 1,022 Check engine mount bracket bolts torques. Engine mount bracket bolts torqued. 0.5 1.0
06-19-08 1,269 The right side bushing is missing on the rear sway bar and the left rear sway bar link is worn. Both rear sway bar bushings and both rear sway bar links replaced. 4.0 1.0
06-20-08 1,376 The right side bushing is missing on the rear sway bar. Bushing replaced. 16.0 1.0
06-23-08 1,424 The crossbar tetween the Mor-Ryde suspension towers is broken. Crossbar welded/repaired. 6.0 1.0
06-26-08 1,555 The left side attaching bracket for the Mor-Ryde suspension is broken. Both attaching brackets for the Mor-Ryde suspension replaced. 43.0 16.0
06-26-08 1,555 Air compressor and air tank for the driver's seat failed. Air compressor and air tank replaced. 1.0 2.0
07-03-08 1,995 The right rear leaf spring is broken. Right rear leaf spring replaced. 6.0 13.5
07-08-08 2,197 The right side rear sway bar bushing is missing. Both rear sway bar bushings replaced. 4.0 0.5
07-10-08 2,274 Manufacturer requests the Mor-Ryde suspension be removed and the OEM suspension installed. Mor-Ryde suspension removed and the OEM suspension installed. 67.0 12.0
07-10-08 2,274 The left rear spring beam is worn. Left rear spring replaced. 24.0 6.0
07-10-08 2,274 The clamp at the muffler outlet is broken. Replaced clamp. 1.5 4.5
07-10-08 2,274 The engine mount bracket bolts are worn. All engine mount bracket bolts replaced. 6.0 4.0
07-23-08 2,743 The OEM bump stops need to be removed for installation of Roll Gurad stabilizers. OEM bump stops removed and Roll Guard stabilizers installed. 6.0 4.0
07-30-08 3,069 The floor structure spot welds above the cab mounts are breaking. Floor covering removed. Realigned floor section and repaired damaged section with rivet and welding. 32.0 18.0
08-11-08 3,840 The air tank is broken from the mounts and leaking. Air tank replaced. 0.5 1.0
08-11-08 3,840 The front radiator mounts are worn. Front radiator mounts replaced. 3.5 6.5
08-11-08 3,840 The floor structure spot welds above the cab mounts are breaking. Welding and repaired floor. 20"x6" plate added. 168.0 14.0
08-18-08 3,840 The floor structure is breaking away. Floor plates installed (top) to repair cracked floor area. 128.0 21.0
08-18-08 3,840 Manufacturer requests all four rear shocks be replaced. All four rear shocks replaced. 1.0 3.0
08-18-08 3,840 The left rear roll guard shackle is damaged. Left rear roll guard shackle replaced. 6.0 1.0
08-27-08 3,955 The transmission bell housing is cracked. Axle removed for towing to repair shop. Transmission reinstalled. 344.0 32.0
08-18-08 3,840 The left rear roll guard shackle is damaged. Left rear roll guard shackle replaced. 6.0 1.0
08-11-08 3,840 The floor structure is breaking away. All four rear shocks replaced. 1.0 3.0
09-15-08 4,049 Mounting bolts for the rear sway bar are broken and the left side bushing has worked out. Broken mounting bolts replaced and bushing replaced. 8.0 3.5
09-15-08 4,049 The weather strip is coming off the driver's door. Weather strip reattached. 0.25 0.5
09-16-08 4,206 The engine will accelerate unexpectedly. Troubleshooting found the attaching nuts on the throttle pedal loose. Nuts tightened. Bus road tested. 6.0 2.0
09-18-08 4,242 The CNG fuel line at the right side fuel tank broke and is leaking CNG fuel (Break at the tank fitting). Fuel line replaced. 40.0 3.0
09-22-08 4,492 The bottom leaf of the right rear spring beam is broken. Broken leaf replaced from used spring beam. Spring beam installed. 8.0 8.0
09-23-08 4,676 The mounting bolts on the right rear sway bar bracket are loose. Mounting bolts replaced on the right rear sway bar mounting bracket. 1.0 1.0
09-29-08 4,862 "Check Engine" and "Reduced Engine Power" lights are on. Throttle is not responding. Troubleshoot codes with "Genisys" reader. Check connections, wiring harnesses. Replaced throttle position sensor. No change in performance. 78.0 3.0
10-10-08 5,012 Manufacturer requests the following work be performed: new rear spring hangers installed for new multi-leaf springs, a tube installed between the frame rails at new rear spring hanger location, new body bushings be installed on right side frame rail, 2.5" x 2.5' angle installed on underside of frame rails. Both rear taper springs be replaced with mulit-leaf springs and both front springs replaced. Tube installed between the frame rails at the new spring hanger locations. New rear springs hangers for mulit-leaf springs installed. New body bushings installed. 2.5"x2.5" angle welded to underside of both frame rails. Rear taper springs replaced with multi-leaf springs. 290.0 80.0
10-21-08 5,354 The fuel line on the right side fuel tank is leaking. Manufacturer's rep replaced broken fuel line with flexible line. 32.0 1.0
10-23-08 5,786 The right front tire is flat. Right front tire replaced. 4.0 2.0
10-29-08 5,892 The right side frame rail is broken approximately 16" from the rear. Installed 32" long x 2.5"x3.5"x3/16" liner. Eight holed for plug welds drilled. Liner installed and plug welds welded. 104.0 18.0
10-30-08 5,892 The exhaust y-pipe is cracked. Craked y-pipe welded/repaired. 4.0 4.5
11-05-08 6,625 Four nuts and bolts are missing from the radiator support. Four nuts and bolts replaced. 2.0 1.0
11-05-08 6,625 The throttle potentiometer failed. Throttle potentiometer replaced. 3.0 2.0
11-05-08 6,625 The windshield washer reservoir is broken. Windshield washer reservoir replaced. 1.0 1.0
11-07-08 6,643 The engine is intermittently accelerating on its own. Manufacturer rep replaced the throttle actuator. 40.0 2.0
11-17-08 7,243 2 engine isolators and 2 transmission mounts have failed causing exhaust crossover gaskets to fail. Front cross member removed for access; 2 engine isolators and 2 transmission mounts replaced. Exhaust crossover gaskets and exhaust manifold gasket replaced. Front crossmember reinstalled. 65.0 15.5
11-17-08 7,243 The CNG fuel filter needs replaced. CNG fuel filter replaced. 2.0 0.5
11-20-08 7,941 Assisted manufacturer rep with trouble shooting electrical short in the clearance light circuit. No problem found. 2.0 2.0
11-20-08 7,941 The radiator surge tank mounting bracket is broken. Broken mounting bracket welded/repaired. 3.0 3.0
11-24-08 8,332 The radiator surge tank mounting brackets are broken. Brackets welded/repaired. 8.0 1.0
12-02-08 9,001 The center bolt is broken on the left rear spring. Broken center bolt replaced. 6.0 4.0
12-03-08 9,183 The radiator surge tank mounting brackets are broken. Manufacturer rep replaced brackets. 1.0 1.0
12-03-08 9,183 The rubber guides on the engine hood are broken and the passenger door hinge pin fell out. Manufacturer rep replaced rubber guides for hood and hinge pin in passenger door. 0.5 0.5
12-04-08 9,415 The bolts are missing on the right rear sway bar link bracket. Missing bolts replaced. 0.5 1.0
12-04-08 9,415 The bolts are missing on the right rear sway bar link bracket. Missing bolts replaced. 0.5 1.0
12-04-08 9,415 The floor panels are breaking out at the entrance door corners. Floor panels welded back into place. 5.0 5.0
12-04-08 9,415 The left front spring is broken. Left front spring replaced. 1.0 2.0
12-09-08 10,156 Test bus shut down on Durability Track, would not start. Negative side battery cable is broken. Negative cable replaced and terminals cleaned. 4.0 2.5
12-16-08 10,938 The second spring ply from the top is broken on the left rear spring. Left rear spring replaced. 54.0 4.0