Item 3: 1983 Chassis Restoration – Brake Relays
The transition from 96-inch to 8-foot wide buses occurred between late 1983 and early 1984. This change was as significant as the shift from the XL to the XLII models around 1999-2000.
Key Points:
- Brake Relays: Pre-1984, 96-inch wide buses used R6 relays, not R12. These relays are quite unique and can be hard to distinguish from the photos, especially if you’re unfamiliar with them.
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Copper Plumbing: Pre-1984 models have all-copper plumbing, making it difficult to replace parts with anything other than perfect matches. According to Prevo Elgin, the bus was originally built with R6 relays.
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Parts Issues: Prevo parts erroneously sent R12 relays instead of the R6. The R12s would require extensive modifications to the plumbing due to differing crack pressures, which could impact the system’s performance. This discrepancy has been confirmed by several sources, including fleet specialists and Bendex.
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New Old Stock: We found R6 relays on eBay for $25 each. They haven’t been installed yet, but once in hand, the replacement will be straightforward. The front relay is accessible after removing several components, while the rear one is more easily reached by removing the bed base and engine hatch.
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Final Note:
Replacing these relays is crucial for maintaining the bus’s performance. The R6 is unique to these early models, and addressing this part while deep into the restoration ensures no stone is left unturned. This 1983 chassis restoration is shaping up to be one of the most significant improvements since it left the Liberty factory 37 years ago.