22E078 – Missing or Loose Brake Pedal Locking Screw – ZF North America

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-078
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
ZF North America, Inc. SEP 27, 2022 NHTSA Recall No. : 22E-078 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : ZF North America, Inc.
Address : 12001 Tech Center Drive
Livonia MI 48150 Company phone : 7348552600
Population :
Number of potentially involved : 137 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : ZF
IPU (Integrated Pedal Unit) Part No. : 9650019900 Size : 329.8 x 332 / 426 (mm) Function : Service brake
Descriptive Information : On affected units, the locking screw of the shaft maintaining the brake pedal is potentially not present or it may not be fully threaded. The relevant ZF part number is 9650019900 (C-Samples).
Production Dates : JUN 30, 2021 – APR 08, 2022
Description of Defect :
Description of the Defect : The shaft locking screw maintaining the brake pedal may potentially be missing or it may not be fully threaded. If the shaft locking screw is missing or insufficiently seated, under certain conditions there is the potential for the shaft to move from its guidance and for the brake pedal to fall off.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Loss of brake pedal function, increasing the risk of a crash.
Description of the Cause : Based on available information, there are two potential causes, both involving the assembly process: (1) electrical screwdriver may not have been linked to automatic sequence control; and (2) necessary tightening operation may have been skipped at the assembly station. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 22E-078 Page 2 Involved Components : Component Name : IPU
Component Description : Integrated Pedal Unit Component Part Number : 9650019900 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On September 6, 2022, a ZF employee received a field complaint from a foreign market. Based on photo documentation of this incident, ZF immediately contained potentially affected parts and initiated an investigation. Based on available information, ZF determined on September 9, 2022 that the observed condition presented a potential safety risk in the markets where the component was available. ZF continued to investigate whether there were any vehicles equipped with the suspect part that were intended for, or shipped into, the U.S. market. On September 13, 2022, ZF subsequently determined that suspect parts had been shipped to the United States and were potentially in the field. At that time, ZF made the decision to submit a Part 573 report to NHTSA. ZF also communicated that decision to its vehicle manufacturer customer verbally on September 13, 2022. To date, ZF has received no warranty claims or reports of accidents or injuries related to this condition. Description of Remedy :
Description of Remedy Program : ZF has alerted its vehicle manufacturer customer of the potential safety-
related defect in this original equipment. Any owner notification, remedy program, and quarterly reporting will be conducted by the vehicle manufacturer; accordingly, ZF is not providing a dealer and owner notification schedule. ZF will support the vehicle manufacturer’s recall by providing detailed instructions for identifying, diagnosing and repairing or replacing affected components that may have missing or under-torqued screws.
How Remedy Component Differs Replacement IPU units have been assembled using an automatic sequence The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-078
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The information contained in this report was submitted pursuant to 49 CFR §573
from Recalled Component : tightening process. Remedied components will have a shaft locking screw present per specification. Identify How/When Recall Condition was Corrected in Production : ZF upgraded its assembly process on April 08, 2022 with an automatic sequence tightening process to secure the final product. Recall Schedule :
Description of Recall Schedule : ZF has notified its customer about the issue and will work with it to
address the issue with owners. ZF does not have dealers or distributors for the affected parts; therefore, it has not populated the Planned Dealer Notification portion of this report and will not be issuing a dealer notification.
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 : Nikola Corporation Address : 4141 E. Broadway Rod. Phoenix AZ 85040 Country : US
Company Phone : 8884299216
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-078
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
ZF North America, Inc. SEP 20, 2022 NHTSA Recall No. : 22E-078 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : ZF North America, Inc.
Address : 12001 Tech Center Drive
Livonia MI 48150 Company phone : 7348552600
Population :
Number of potentially involved : 137 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : ZF
IPU (Integrated Pedal Unit) Part No. : 9650019900 Size : 329.8 x 332 / 426 (mm) Function : Service brake
Descriptive Information : On affected units, the locking screw of the shaft maintaining the brake pedal is potentially not present or it may not be fully threaded. The relevant ZF part number is 9650019900 (C-Samples).
Production Dates : JUN 30, 2021 – APR 08, 2022
Description of Defect :
Description of the Defect : The shaft locking screw maintaining the brake pedal may potentially be missing or it may not be fully threaded. If the shaft locking screw is missing or insufficiently seated, under certain conditions there is the potential for the shaft to move from its guidance and for the brake pedal to fall off.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Loss of brake pedal function, increasing the risk of a crash.
Description of the Cause : Based on available information, there are two potential causes, both involving the assembly process: (1) electrical screwdriver may not have been linked to automatic sequence control; and (2) necessary tightening operation may have been skipped at the assembly station. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 22E-078 Page 2 Involved Components : Component Name : IPU
Component Description : Integrated Pedal Unit Component Part Number : 9650019900 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On September 6, 2022, a ZF employee received a field complaint from a foreign market. Based on photo documentation of this incident, ZF immediately contained potentially affected parts and initiated an investigation. Based on available information, ZF determined on September 9, 2022 that the observed condition presented a potential safety risk in the markets where the component was available. ZF continued to investigate whether there were any vehicles equipped with the suspect part that were intended for, or shipped into, the U.S. market. On September 13, 2022, ZF determined that suspect parts had been shipped to the United States and were potentially in the field. At that time, ZF made the decision to submit a Part 573 report to NHTSA. To date, ZF has received no warranty claims or reports of accidents or injuries related to this condition. Description of Remedy :
Description of Remedy Program : ZF has alerted its customer of the potential safety-related defect. ZF’s
customer will conduct any applicable remedies. ZF will work with its customer to provide detailed instructions for identifying, diagnosing and repairing or replacing affected components that may have missing or insufficiently seated screws. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Replacement IPU units have been assembled using an automatic sequence tightening process. Remedied components will have a shaft locking screw present per specification.
ZF upgraded its assembly process on April 08, 2022 with an automatic sequence tightening process to secure the final product. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-078
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The information contained in this report was submitted pursuant to 49 CFR §573
Recall Schedule :
Description of Recall Schedule : ZF has notified its customer about the issue and will work with it to
address the issue with owners. ZF does not have dealers or distributors for the affected parts; therefore, it has not populated the Planned Dealer Notification portion of this report and will not be issuing a dealer notification.
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 : Nikola Corporation Address : 4141 E. Broadway Rod. Phoenix AZ 85040 Country : US
Company Phone : 8884299216
* NR – Not Reported

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