1998 Metrotrans Legacy LJ

Below you will find all the info I could drag up on this bus.

Basic Bus Info

• 1998 Metrotrans Legacy LJ model
• 5.9L 24v 210hp ISB Cummins Turbo Diesel Engine
• Allison AT545 Transmission
• Rear Differential is a Dana 80 with 4.56gears
• Chassis is a Custom made chassis for Metrotrans by Spartan Chassis. Model is a BC-2242.
• MFD by Metrotrans Corp. Griffin, GA 30223
• Date of MFR: 12/98
• INC. VEH MFD BY: Spartan Motor Company
• Date of Inc Veh Mfr: Nov 1998
• Vehicle Type: 99-L30-01241
• GVWR: 8618 kg or 19000 lb
• GAWR-Front: 3175 or 7000 lb
• GAWR-Rear: 5443kg or 12000 lb
• Last Weighed in at 15,013lbs with no interior and half tank of gas.

Engine

• Engine: 1998 Cummins 5.9l Turbo-Diesel 24v
• Model: ISB 210
• Date of Manufacture: 1998-03-16
• Timing: T.D.C. 1.50MM
• Valve Lash Cold:0.010 Int. 0.020 Exh.
• Firing Order: 1 5 3 6 2 4
• Idle Speed: 800
• E.C.S. PCM
• Advertised HP: 210 at 2500rpm
• Ref Number: B435-AA2-002
• Engine Number: 45670999
• Family: WCEXH0359BAE
• Fuel rate at adv. HP: 93 mm3/ stroke
• FEL | EPA
• Nox | 4.0
• Pm. | 0.10
• Exhaust Manifold is from a 6B, not a 98.5-2002 ISB: Part Numbers 3943872 and 3943875
• Exhaust Turbo Studs Part Numbers: Nut 3818824, Stud 3818823, Qty4 of each
• Exhaust Manifold bolts.: PN 3944593, Qty 12
• Exhaust Manifold Bolt w Stud: PN 3920346
• Exhaust Manifold Bolt Spacer: PN 3945252, Qty ?
• Stock Injectors(Cleaned and re-installed): Bosch 0432193647
• Stock Injector Feed Tubes(Cleaned and re-used): F00ZR20000. 3942192
• Upgraded Injectors(coming soon): Bosch RV275, 0432193635, Apparently a 40-60Hp gain

Transmission

• Allison AT 545 SN: 3210675374. Stock Number: 38263. Part Number: E001003
• Transmission Oil: Dexron® III, C4
• Capacity: 20.0 qts (18.9 liters) standard oil pan
• Other Info: www.messb.com.my/allison_at_545.html
• Gear Ratios 1st/3.45. 2nd/2.45, 3rd/1.41, 4th/1.

Differential Info

• Dana/Spicer 80, with 4.56 gear ratio
• https://en.wikipedia.org/wiki/Dana_80#:~:text=The%20Dana%2FSpicer%20Model%2080,80%22%20cast%20into%20the%20housing.
• https://www.differentials.com/technical-help-2/differential-identification/#:~:text=Visual%20Differential%20Identification,an%20integral%20or%20dropout%20design.
• Fluid: Some say regular 80-90, Some say 75-90w Synthetic, some say 75-140w Synthetic if towing. I’m going to use Mobil 1 75-90w Synthetic.
• Capacity: 3-5qts, Not sure if it’s Limited Slip. I didn’t see a LS on the Tag so I’m going to assume no.
• $2700 to rebuild and re-gear at Weller. Core charge of $1500. Weller Part No. DANA80R331WEL

Front Axles

• Westport
• Front Axle Hub cover for oil bath: SKF Oil Fill Hubcap Bearing Cap Seal 1681 For Ford Freightliner

Chassis Info

• Spartan Chassis Model Number: BC-2242
• Designed Exclusively for the Metrotrans Legacy LJ by Spartan

VIN Decoded

• VIN: 4VZTH719OWC******
• VIN Decoded:
• 4VZ=Cabless Chassis
• T=BC
• H=16000-19500/Hydraulic GVWR/Brake System
• 71=Cummins ISB 210HP
• 9=Multi-Passenger Cab Type
• 0=Check Digit
• W=Model Year 1998
• C=Plant Location, Charlotte, MI
• ******= Serial Number

Suspension Info

• Shocks, Front: Old Bilstein Number F4-B46-1731-M1. New Bilstein Number 24-017312
• Shocks, Rear: Old Bilstein Number F4-B46-1732-M1. New Bilstein Number 24-017329

Interior Info

It was a 33 Passenger bus

Engine Accessories Info

• Turbo: Holset HX35W

Metrotrans Legacy LJ Model Info

• Model Info: THE LEGACY LJ.  In 1995, Metrotrans introduced the Legacy LJ, a down-sized rear engine coach accommodating up to 33 passengers and built on a Spartan BC-2242 chassis designed exclusively for Metrotrans.  A product that fills a gap between a cutaway chassis shuttle bus and a full-size motor coach, the Legacy LJ offers the image and reliability of a coach with the maneuverability of a shuttle bus featuring a 16 foot, 4 inch turning radius which allows operation in narrow streets or compact parking lots. 
• Legacy LJ……… Suggested Retail $75,000 to $85,000 came in 26ft and 30ft models, 33Passengers, 175hp or 210 hp

Alternator Info

• LEECE NEVILLE: 4860J 4860JB A0014860JB A0014860JBH
• ITEM DESCRIPTION: ALTERNATOR
• UNIT TYPE: LEECE NEVILLE
• VOLTAGE: 12
• AMPERAGE: 200
• FAN: INTERNAL
• REGULATOR: INTERNAL
• REGULATOR CLOCK: 12:00
• POLARITY: NEGATIVE
• B+ TERMINAL: 5/16-18
• WEIGHT: 32.75 LBS / 14.89 KG
• Regulator Install Guide: https://www.prestolite.com/literature/tech/alts/TSB-1045_102200_regulator_installation.pdf
• Wiring Info: https://www.prestolite.com/pgs_products/specs.php?item_detail_id=859&item=A0014864JB
• Service Manual: https://www.prestolite.com/literature/tech/alts/TSM1001_4000_Series_Int_Reg_and_Rectifier_Service-Manual.pdf

Maintenance Info

• Check/adjust valve lash: 150,000 miles, Done at 166k in 2022
• Oil. 12quarts Rotella 15w-40, changed 2022 at 166k
• Oil Filter: WIX 57182, changed 2022 at 166k
• Oil Change Interval: 7500 miles/ 6 month of normal driving conditions | 3,750 miles under severe driving conditions
• Air Filter: WIX – WA10116, cleaned 2021
• Fuel Filter: WIX – 33585XE, changed 2022 at 166k
• Hydraulic Fluid Filter: Baldwin BT839: WIX-51553, changed 2022 at 166k
• Coolant Change Interval: 30,000 miles/24 months
• Inspect water pump: 15,000 miles (inspect weep hole for blockage), replaced 2022

Tire Info

• Tire Size: 8r19.5
• Spare Tires: Dynatrac RA200, Circa 2018
• Replaced all 6 Tires with Americus AP200 June 2024, added 8oz balance beads to all 6 tires.
• (OLD)Rear Tires: Triangle TR656 Date Code 44th Week of 2010
• Rim Size: Accuride 19.5″ x 6″ 6 Lug
• Lug Torque: 400ft/lb ish

Misc Info

Brakes Info

• Brake Light switch: Cole Hersee 91126-BX Switch: Link to Buy
• Brake Hydraulic Booster: HYDROMAX BRAKE BOOSTER 2772114 or CARDONE 527398
• Electric brake booster for Hydraulic brake System: Prestolite motors HYL-5006 (2772876)
• Master Cylinder 2 in. bore diameter; 1/2-20 Forward Outlet Size Forward Outlet Size; 9/16-18 Rearward Outlet Size : The original casting number is Bosch 2239045. I think it’s also a Cardone Industries 138042 or Dorman M630277
• Front Rotors: TBD
• Front Calipers: BrakeBest 18-4842 or Cardone 18P4842 (These seem nicer as they are powder coated) (Used a 98 GMC T6500 with 6.6l for Parts lookup at O’Reilly)
• Front Pads: BrakeBest MKD224
• Rear Rotors: TBD
• Rear Calipers: BrakeBest 18-4842 or Cardone 18P4842 (Used a 98 GMC T6500 with 6.6l for Parts lookup at O’Reilly)
• Rear Pads: BrakeBest MKD224
• Brake Hardware: In case your calipers come without it. CENTRIC 11779001

Fuel System Info

• Electronically controlled Bosch VP44 rotary injection pump. Looks to be a newer remanufactured unit.
• Replaced all 6 Injectors 4/2019 with rebuilt injectors from Pensacola Diesel. New Injector tubes at same time.
• Re-Replaced the injectors with the original Injectors 5/2022, the rebuilt ones were not great. I rebuilt them and ran them through an ultrasonic cleaner and they work great now.
• Replaced Fuel Pump and Fuel Filter 4/2019, with FASS DRP replacement pump as the original Carter SUCKED. I put in a fuel gauge and the Brand new Carter hit 0psi at 55mph, the new Fass is 14 at idle and 10 at 55mph.

Dash Gauges Info

GlowShift Oil Pressure Gauge

Diesel Heater, eBay Chinese Special 5kw

Misc Pictures