June 17, 2022 NHTSA CAMPAIGN NUMBER: 22V436000
EV System May Switch into Neutral Unexpectedly
An unexpected switch to neutral can cause a loss of vehicle propulsion and increase the risk of a crash.
NHTSA Campaign Number: 22V436
Manufacturer Gillig
, LLC
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 169
Summary
Gillig, LLC (Gillig) is recalling certain 2019-2022 Low Floor electric transit buses. The EV resolver cable connector may experience a loss of electrical connectivity, unexpectedly switching from Drive to Neutral with no warning.
Remedy
Dealers will install a redesigned resolver cable with extended length and a new support bracket, free of charge. Owner notification letters were mailed on August 3, 2022. Owners may contact Gillig’s customer service at 1-510-264-5073 or 1-800-735-1500.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Gillig has decided that certain model year 2019 through 2022 Low Floor battery electric buses, manufactured between 05/29/2019 and 04/08/2022 contain a defect related to motor vehicle safety. The affected vehicles may experience unexpected transition from Drive to Neutral mode while the vehicle is in motion with consequent loss of propulsion. The defect is due to loss of electrical continuity of the resolver cable connector. When the signal is lost, the EV control system immediately actuates a switch from Drive to Neutral mode with no advanced warning to the driver. An unexpected switch to neutral can cause a loss of vehicle propulsion and increase the risk of a crash.
As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign of the vehicle population that may be affected by the issue.
Chronology :
On 3/4/2022 GILLIG Service received the first report of a vehicle switching unexpectedly from Drive to Neutral mode.
Between 3/4 and 3/24 GILLIG received seven (7) additional reports related to the same issue
On 4/4/2022 GILLIG engineering initiated the analysis of the external and internal EV system cables with support of the propulsion system manufacturer Cummins.
05/24/2022 GILLIG confirmed the root cause of the issue through vehicle testing and decided to design a new longer cable and a new support bracket to provide more robust connector strain relief.
On 6/10/2022 based upon the information developed during the investigation, the GILLIG Safety Committee decided to conduct a safety campaign to address this issue.
On 6/17/2022 GILLIG completed population analysis and identified 169 vehicles that may be affected by this defect.
On 06/17/2022 GILLIG filed a safety recall with NHTSA
4 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| GILLIG | LOW FLOOR | 2019-2022 |
6 Associated Documents
Defect Notice 573 Report
RCLRPT-22V436-6412.PDF 215.607KB
Recall Acknowledgement
RCAK-22V436-2125.pdf 646.058KB
Recall Quarterly Report #1, 2022-3
RCLQRT-22V436-2002.PDF 211.124KB
Recall Quarterly Report #2, 2022-4
RCLQRT-22V436-5513.PDF 211.224KB
Issued Owner Notification Letter (Part 577)
RCONL-22V436-3618.pdf 72.006KB
Recall Quarterly Report #3, 2023-1
RCLQRT-22V436-9982.PDF 211.307KB
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SEOCONTENT-START
IMPORTANT SAFETY RECALL NOTICE Gillig Campaign ID Number: 22V-436 This notice applies to your vehicle(s) [insert VINs]
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