22E049 – EQ-J2044 – Corrosion May Cause Fuel Line Leak – Roush – GEN 4 & GEN 5 LPG Conversion Systems

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-049
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Roush CleanTech, LLC
Submission Date : JUN 09, 2022
NHTSA Recall No. : 22E-049
Manufacturer Recall No. : EQ-J2044
Manufacturer Information :
Manufacturer Name : Roush CleanTech, LLC
Address : 12170 Globe Street
Livonia MI 48150
Company phone : 800-597-6874
Population :
Number of potentially involved : 12,823
Estimated percentage with defect : 52 %
Equipment Information :
Brand / Trade 1 : Roush Cleantech
Model : Fuel Return Lines in GEN 4/5 LPG Conversion Systems
Part No. : Pls see Mfr Comments
Size : NR
Function : Fuel Return
Descriptive Information : The population of items of original equipment covered by this report does not
include fuel return lines manufactured prior to July 2015 because that date is
when Roush began to use zinc-plated fittings on those return lines.
Roush’s conclusion that this report does not apply to fuel return lines that were
installed in vehicles that were not operated in the Salt Belt states is based
primarily on the following: (1) all of the 19 warranty claims that reported
corrosion of a fuel return line fitting came from vehicles in the Salt Belt states;
(2) Roush’s inspection of 166 vehicles from various regions of the United States
(the results of which are described in the “Describe the Cause” section of this
report) demonstrated that there has been extremely little, if any, corrosion of
fittings on vehicles outside of the Salt Belt states.
Production Dates : JUL 30, 2015 – JUN 01, 2022
Part 573 Safety Recall Report 22E-049 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Defect :
Description of the Defect : Some zinc-plated carbon steel fuel return line fittings on Gen 4 and Gen 5
Roush Cleantech LPG fuel conversion kits installed on vehicles operated in the
Salt Belt states have exhibited galvanic-reaction-caused corrosion where the
stainless-steel crimp collar on the fuel return line contacts the zinc-plated
carbon steel fitting, if the zinc-plating has been compromised by road debris
pecking. If this occurs, there is a risk that the fuel line fitting could corrode to
the point where LPG fuel will leak.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : If the fuel return line leaks, it could increase the risk of a fire.
Description of the Cause : Roush believes that a galvanic reaction can occur in Salt Belt state road
conditions (i.e., a combination of road debris pecking on the zinc-plated carbon
steel fitting, and road salt and moisture from snow/ice/water). This galvanic
reaction can create the potential for compromised zinc plating to corrode the
carbon steel LPG fuel return line fittings where the stainless-steel crimp collar
contacts the fitting.
Roush has concluded that this problem is limited to vehicles operated in the
Salt Belt states. Roush inspected (and rated for degree of corrosion on a scale of
1 (like new) to 6 (leaking)) the fittings on 166 representative vehicles (altered
Ford E/F Series vehicles and Blue Bird school buses) in multiple regions of the
country. Of the 70 vehicles inspected and rated in the non-Salt Belt states, 55
were rated #1 (still looking new with the zinc plating intact), and the
remaining 15 were rated #2 (little to no rust showing on the fittings).
Conversely, of the 96 vehicles inspected in the Salt Belt states, only 8 received a
#1 rating, 45 were rated #2, and 43 rated either #3 (red rust greater than/
equal to 50% of the inspected part) or higher.
Identification of Any Warning
that can Occur :
It may be possible to observe a significant amount of red rust on the fuel return
line connector fitting prior to any fuel leak.
Involved Components :
Component Name : ¼” fuel return line
Component Description : Fuel return line assembly that includes a zinc-plated carbon steel fitting and
stainless-steel crimp collar.
Component Part Number : See MFR Comments
Supplier Identification :
Part 573 Safety Recall Report 22E-049 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Component Manufacturer
Name : Detroit Flex Defense
Address : 2921 Industrial Row
Troy Michigan 48084
Country : United States
Chronology :
In Oct 2020, Roush was informed that two Blue Bird school buses in PA had experienced apparent corrosioncaused
fuel return line fitting failures about 3 weeks apart. Roush started to investigate service history,
engineering, and supplier quality. Several additional similar warranty claims were reported in 2021. By Spring
2022, Roush had received a total of 19 corrosion warranty claims, with no fires. These claims arose solely in
Salt Belt states and involved vehicles with various mileage and manufacturing dates.
Roush began its Salt Belt and non-Salt Belt geographic field and laboratory investigation in 2021. In total,
Roush inspected (and rated for degree of corrosion) the fittings on more than 166 representative vehicles as
described in the “Describe the Cause” section above. The inspections identified the vehicle make, model, part
number, part location, orientation, mileage, alteration date, geographic location, and route characteristics.
Some non-leaking fittings observed with exterior corrosion were dissected to ascertain the extent of any
internal compromised metal.
Roush also conducted two types of laboratory salt spray testing. The ASTM B117 salt spray testing varied the
orientation of the fittings in the salt test chamber (parallel to ground, perpendicular, 45 degrees, reversed male
tube directions). Roush’s modified salt spray testing included a road debris pecking simulation. Roush then
tested fittings equipped with additional spiral wrap protection, with braided loom protection, and with a
combination of the two protections.
Based on the results of its investigation, in late May 2022, Roush decided to submit this report.
Description of Remedy :
Description of Remedy Program : Roush will work with Blue Bird and alterers (and their applicable servicing
dealers) to replace the fuel return lines in the recalled vehicles.
Replacement fuel return lines will include a new 5” spiral wrap covered
with a 9” braided loom zip tied at each end of the spiral wrap (the “Wrap &
Loom protection”). All parts and material will be supplied by Roush.
Applicable servicers will be reimbursed by Roush for all associated labor
costs.
How Remedy Component Differs
from Recalled Component :
The remedy fuel return lines will all have the Wrap & Loom protection in
place. The addition of the combined Wrap & Loom protects the carbon
steel zinc-plating on the fitting from road debris pecking damage. Intact
zinc-plating reduces the adverse potential galvanic reactions exacerbated
by salt and moisture.
Part 573 Safety Recall Report 22E-049 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition
was Corrected in Production :
Roush implemented the Wrap & Loom protection in its production of fuel
return lines for alterers of Ford E/F Series commercial vehicles on
November 16, 2021. Due to Blue Bird’s different manufacturing, quality
and assembly requirements, Blue Bird is containing all buses assembled
after June 7, 2022 at Blue Bird’s facility and Roush will be installing the
Wrap & Loom protection at the end of the production line.
Recall Schedule :
Description of Recall Schedule : With respect to the items of original equipment covered by this report,
Roush will not be conducting a recall. Rather, recalls will be conducted –
with Roush’s cooperation – by Blue Bird and various alterers. Roush
plans to send a copy of this report to Blue Bird and the alterers promptly
after it is submitted to NHTSA.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : A1 Alternate Fuels
Address : 3608 Cooper Dr.
Elkhart IN 46514
Country : US
Company Phone : 5596966340
Name : Creative Bus Sales – Chino
Address : 14740 Ramona Ave.
Chino CA 91710
Country : US
Company Phone : 9094655528
Name : Hoekstra
Address : 3701 Roger B. Chaffee Blvd.
Grand Rapids MI 49548
Country : US
Company Phone : 8004444104
Part 573 Safety Recall Report 22E-049 Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
Name : National Fleet Services – Detroit
Address : 10100 Grinnell Ave
Detroit MI 48213
Country : US
Company Phone : 4409375177
Name : Rush Truck Center – Dallas
Address : 4000 Irving Blvd
Dallas TX 75247
Country : US
Company Phone : 8669054466
Name : Blue Bird Body Company
Address : 402 Blue Bird Boulevard
Fort Valley GA 31030
Country : US
Company Phone : 4783026410
Name : Coach & Equipment
Address : 130 Horizon Park Dr.
Penn Yan NY 14527
Country : US
Company Phone : 3155362321
Name : Creative Bus Sales – Elkhart
Address : 57457 County Rd. 3
Elkhart IN 46517
Country : US
Company Phone : 8889260620
Name : Creative Bus Sales – Mukilteo
Address : 1161 Cyrus Way #101
Mukilteo WA 98275
Country : US
Company Phone : 4256091500
Name : Manning Equipment – Ohio
Address : 5200 Oster Rd.
Sheffield OH 44054
Country : US
Company Phone : 4409491337
Part 573 Safety Recall Report 22E-049 Page 6
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Microbird, Inc.
Address : 3600 Rue Girardin
Drummondville 00 J2E0A1
Country : CA
Company Phone : 8194772012
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-049
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Roush CleanTech, LLC
Submission Date : APR 19, 2023
NHTSA Recall No. : 22E-049
Manufacturer Recall No. : EQ-J2044
Manufacturer Information :
Manufacturer Name : Roush CleanTech, LLC
Address : 12170 Globe Street
Livonia MI 48150
Company phone : 800-597-6874
Population :
Number of potentially involved : 8,385
Estimated percentage with defect : NR
Part 573 Safety Recall Report 22E-049 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Equipment Information :
Brand / Trade 1 : Roush CleanTech
Model : Fuel Return Lines in GEN 4/5 LPG Conversion Systems
Part No. : Pls see Mfr Comments
Size : NR
Function : Fuel Return
Descriptive Information : The items of original equipment covered by this report do not include LPG
systems manufactured prior to July 2015 because that date is when Roush began
to use zinc-plated fittings on the fuel return lines in its LPG conversion kits.
The population does not include LPG systems shipped after June 30, 2022
because LPG systems shipped after that date had fuel return lines with additional
protection that prevents the corrosion at issue here.
Because the corrosion at issue here occurs only in the presence of significant
amounts of road salt, this notice applies only to the fuel return lines in LPG
conversion kits installed in vehicles originally or currently registered in the
following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana,
Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri,
New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island,
Vermont, Virginia, West Virginia, and Wisconsin (which are referred to in this
Report as the “Salt Belt States”).
Roush sold 12,886 LPG conversion kits as original equipment. 8,385 of those kits
were installed on vehicles originally or currently registered in the Salt Belt
States. Roush installed 1,812 of the above 8,385 kits and Roush separately
reported those 1,812 kits on its Vehicle Alterer Report NHTSA ID: 22V408. The
remaining 6,573 kits on this Equipment Report were installed by Blue Bird and
the alterers (identified in the Purchaser Information section below) that
purchased the kits as original equipment.
Production Dates : JUL 30, 2015 – JUN 30, 2022
Description of Defect :
Description of the Defect : Some zinc-plated carbon steel fuel return line fittings on Gen 4 and Gen 5
Roush Cleantech LPG fuel conversion kits installed on vehicles operated in the
Salt Belt States have exhibited galvanic-reaction-caused corrosion where the
stainless-steel crimp collar on the fuel return line contacts the zinc-plated
carbon steel fitting, if the zinc-plating has been compromised by road debris
pecking. If this occurs, there is a risk that the fuel line fitting could corrode to
the point where LPG fuel will leak.
FMVSS 1 : NR
Part 573 Safety Recall Report 22E-049 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
FMVSS 2 : NR
Description of the Safety Risk : If the fuel return line leaks, it could increase the risk of a fire.
Description of the Cause : Roush believes that a galvanic reaction can occur under certain road conditions
(i.e., a combination of road debris pecking on the zinc-plated carbon steel
fitting, and road salt and moisture from snow/ice/water). This galvanic
reaction can create the potential for compromised zinc plating to corrode the
carbon steel LPG fuel return line fittings where the stainless-steel crimp collar
contacts the fitting.
Roush has concluded that this problem is limited to vehicles operated in the
Salt Belt States. Roush inspected (and rated for degree of corrosion on a scale
of 1 (like new) to 6 (leaking)) the fittings on 166 representative vehicles
(altered Ford E/F Series vehicles and Blue Bird school buses) in multiple
regions of the country. Of the 70 vehicles inspected and rated in the non-Salt
Belt States, 55 were rated #1 (still looking new with the zinc plating intact),
and the remaining 15 were rated #2 (little to no rust showing on the fittings).
Conversely, of the 96 vehicles inspected in the Salt Belt States, only 8 received a
#1 rating, 45 were rated #2, and 43 rated either #3 (red rust greater than/
equal to 50% of the inspected part) or higher.
Identification of Any Warning
that can Occur :
It may be possible to observe a significant amount of red rust on the fuel return
line connector fitting prior to any fuel leak.
Involved Components :
Component Name : ¼” fuel return line
Component Description : Fuel return line assembly that includes a zinc-plated carbon steel fitting and
stainless-steel crimp collar.
Component Part Number : See MFR Comments
Supplier Identification :
Component Manufacturer
Name : Detroit Flex Defense
Address : 2921 Industrial Row
Troy Michigan 48084
Country : United States
Chronology :
Part 573 Safety Recall Report 22E-049 Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
In Oct 2020, Roush was informed that two Blue Bird school buses in Pennsylvania had experienced apparent
corrosion-caused fuel return line fitting failures about 3 weeks apart. Roush started to investigate service
history, engineering, and supplier quality. Several additional similar warranty claims were reported in 2021.
By Spring 2022, Roush had received a total of 19 corrosion warranty claims, with no fires. These claims arose
solely in Salt Belt states and involved vehicles with various mileage and manufacturing dates.
Roush began its Salt Belt and non-Salt Belt geographic field and laboratory investigation in 2021. In total,
Roush inspected (and rated for degree of corrosion) the fittings on more than 166 representative vehicles, as
described in the “Describe the Cause” section above. The inspections identified the vehicle make, model, part
number, part location, orientation, mileage, alteration date, geographic location, and route characteristics.
Some non-leaking fittings observed with exterior corrosion were dissected to ascertain the extent of any
internal compromised metal.
Roush also conducted two types of laboratory salt spray testing. The ASTM B117 salt spray testing varied the
orientation of the fittings in the salt test chamber (parallel to ground, perpendicular, 45 degrees, reversed male
tube directions). Roush’s modified salt spray testing included a road debris pecking simulation. Roush then
tested fittings equipped with additional spiral wrap protection, with braided loom protection, and with a
combination of the two protections.
Based on the results of its investigation, in late May 2022, Roush decided to submit this report.
Description of Remedy :
Description of Remedy Program : Roush is working with Blue Bird and the alterers who purchased the
defective LPG conversion kits as original equipment (and their applicable
servicing dealers) to replace the fuel return lines in the recalled vehicles.
Roush is supplying all parts and material and covering all labor costs.
Roush has been working with its supplier, Detroit Flex Defense (DFD), to
prioritize the manufacture and supply of newly designed fuel return lines
which vary based upon Roush’s customers’ vehicle wheel base lengths and
tank range configurations (collectively, “Vehicle Configuration”). Due to
limited supply, first priority is to replace lines sold to Blue Bird for school
bus passenger use (in descending order based on Blue Bird’s Vehicle
Configuration volumes) and then to commercial (non-passenger) vehicle
alterers in descending order of the alterers’ Vehicle Configuration
volumes. There are 4,830 Blue Bird buses in different Vehicle
Configurations requiring remedy components. As of April 19, 2023, Roush
is prepared to start shipping replacement Gen 4 fuel return line kits for the
Blue Bird Bus 273 Wheel Base extended range tank configuration (new
fuel line part number P-10R600-BA-10560) (Roush Kit part number
P22BB-RLEXTKIT-FA) that are currently being manufactured by DFD.
Roush will work with Blue Bird to replace the defective fuel return lines on
these configured buses. Subsequent replacement fuel return line kits are
scheduled to be available from DFD for the remaining 13 Blue Bird Vehicle
Configurations and then the alterers’ Vehicle Configurations in descending
order based on volumes.
Part 573 Safety Recall Report 22E-049 Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs
from Recalled Component :
The remedy components from DFD will all have stainless steel fittings.
Identify How/When Recall Condition
was Corrected in Production :
Roush initially corrected the “recall condition” for most of its equipment
items sold to independent alterers in late November 2021 by using a new
5” spiral wrap covered with a 9” braided loom zip tied at each end of the
spiral wrap (the “Wrap & Loom protection”). Due to the current limited
available quantities of stainless steel remedy components from DFD,
Roush anticipates continuing production with the Wrap & Loom
protection until after the recall remedy is completed.
Recall Schedule :
Description of Recall Schedule : With respect to the items of original equipment covered by this report,
Roush is not conducting a recall. Rather, recalls will be conducted – with
Roush’s cooperation – by the purchasers of the LPG conversion kits
covered by this report.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : A1 Alternate Fuels
Address : 3608 Cooper Dr.
Elkhart IN 46514
Country : US
Company Phone : 5596966340
Name : Blue Bird Body Company
Address : 402 Blue Bird Boulevard
Fort Valley GA 31030
Country : US
Company Phone : 4783026410
Part 573 Safety Recall Report 22E-049 Page 6
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Coach & Equipment
Address : 130 Horizon Park Dr.
Penn Yan NY 14527
Country : US
Company Phone : 3155362321
Name : Creative Bus Sales – Chino
Address : 14740 Ramona Ave.
Chino CA 91710
Country : US
Company Phone : 9094655528
Name : Creative Bus Sales – Elkhart
Address : 57457 County Rd. 3
Elkhart IN 46517
Country : US
Company Phone : 8889260620
Name : Rush Truck Center – Dallas
Address : 4000 Irving Blvd
Dallas TX 75247
Country : US
Company Phone : 8669054466
Name : Hoekstra
Address : 3701 Roger B. Chaffee Blvd.
Grand Rapids MI 49548
Country : US
Company Phone : 8004444104
Name : Manning Equipment – Ohio
Address : 5200 Oster Rd.
Sheffield OH 44054
Country : US
Company Phone : 4409491337
Name : Microbird, Inc.
Address : 3600 Rue Girardin
Drummondville 00 J2E0A1
Country : CA
Company Phone : 8194772012
Part 573 Safety Recall Report 22E-049 Page 7
The information contained in this report was submitted pursuant to 49 CFR §573
Name : National Fleet Services – Detroit
Address : 10100 Grinnell Ave
Detroit MI 48213
Country : US
Company Phone : 4409375177
Name : Creative Bus Sales – Mukilteo
Address : 1161 Cyrus Way #101
Mukilteo WA 98275
Country : US
Company Phone : 4256091500
* NR – Not Reported

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