Tie Rod Clamp Failure – 2021-2023 Alexis Fire Spartan Metro Star, FC-94 Fire Trucks

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-879 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Alexis Fire Equipment Company Submission Date : NOV 29, 2022 NHTSA Recall No. : 22V-879 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Alexis Fire Equipment Company Address : 109 E Broadway Ave PO Box 549 Alexis IL 61412 Company phone : 309-482-6121 Population : Number of potentially involved : 20 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2023 Spartan Metro Star, FC-94 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : DIESEL Descriptive Information : Spartan notified all final stage manufacturers that based upon information provided by Meritor’s supplier, due to a heat treat issue, Meritor has determined that a population of tie rod clamps used in the manufacture of the subject axle population may be susceptible to cracking. Over time, a crack may lead to a complete fracture of the clamp, thereby reducing clamp load to the tie rod end. If both clamps on the tie rod were to fail, the cross tube could start to unscrew, vehicle alignment issues would evolve, and there is a potential for the tie rod end to separate from the cross tube. Separation is more likely to occur when tie rod loads are highest, which is at slow vehicle speeds over rough terrain or turning maneuvers. This defect could result in separation of the tie rod end from the cross tube and could result in partial loss of vehicle steering capability, increasing the risk of a crash. The initial effect would be a vehicle out of alignment. If both clamps on the tie rod cracked, the tube could rotate and result in a partial loss of steering capability. Production Dates : JAN 01, 2022 – SEP 30, 2022 VIN Range 1 : Begin : 4S9CU2D9XNC560853 End : 4S9CU2D98NC560121 ✔ Not sequential VIN Range 2 : Begin : 4S9CW2D99NC560918 End : 4S9CU2D93NC560919 Not sequential VIN Range 3 : Begin : 4S9DU2D93NC560987 End : 4S9DU2D9XNC560985 Not sequential VIN Range 4 : Begin : 4S9DU2D91NC560986 End : 4S9DU2D98NC560094 Not sequential VIN Range 5 : Begin : 4S9DU2D90NC560090 End : 4S9DU2D97NC560085 Not sequential VIN Range 6 : Begin : 4S9DU2D9xnC560095 End : 4S9DU2D92NC560088 Not sequential VIN Range 7 : Begin : 4S9DU2D90NC560087 End : 4S9CU2D96NC560946 Not sequential VIN Range 8 : Begin : 4S9DU2D93NC560083 End : 4S9DU2D99NC560086 Not sequential VIN Range 9 : Begin : 4S9DU2D95NC560084 End : 4S9DU2D94NC560089 Not sequential VIN Range 10 : Begin : 4S9CU2D95NC560047 End : 4S9DW2D94PC560249 Not sequential Part 573 Safety Recall Report 22V-879 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Based upon information provided by Meritor’s supplier, due to a heat treat issue, Meritor has determined that a population of tie rod clamps used in the manufacture of the subject axle population may be susceptible to cracking. Over time, a crack may lead to a complete fracture of the clamp, thereby reducing clamp load to the tie rod end. If both clamps on the tie rod were to fail, the cross tube could start to unscrew, vehicle alignment issues would evolve, and there is a potential for the tie rod end to separate from the cross tube. Separation is more likely to occur when tie rod loads are highest, which is at slow vehicle speeds over rough terrain or turning maneuvers. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Separation of the tie rod end from the cross tube could result in partial loss of vehicle steering capability, increasing the risk of a crash. Description of the Cause : Improper heat treatment of the part by Meritor’s suppllier. Identification of Any Warning that can Occur : The initial effect would be a vehicle out of alignment. If both clamps on the tie rod cracked, the tube could rotate and result in a partial loss of steering capability. Involved Components : Component Name 1 : Tie Rod Assembly Component Description : NR Component Part Number : B1-3102N4850 Component Name 2 : Tie Rod Assembly Component Description : NR Component Part Number : B1-3102R4854 Component Name 3 : Tie Rod Assembly Component Description : NR Component Part Number : A1-3102S4855 Part 573 Safety Recall Report 22V-879 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : Meritor, Inc. Address : 2135 West Maple Road Troy Michigan 48084 Country : United States Chronology : 11/22/2022- Spartan notification letter informing of Meritor safety recall 6/27/2022 – Meritor’s supplier shared an 8D related to the supplier’s investigation into cracks on tie rod clamps 7/5 – 7/29/2022 – Meritor’s engineering team developed and finalized a technical position regarding the cracked clamps issue. 7/28/2022 – Meritor’s PSAC council reviewed the technical position paper and decided to communicate the issue to its customers as a customer satisfaction issue. 9/16/2022 – Autocar, LLC filed a Part 573 Defect Information Report (DIR) related to this condition. See Recall No. 22V697. 9/22/2022 – Navistar filed a Part 573 Defect Information Report related to this condition. See Recall No. 22V711. 9/30/2022 – Based upon the Part 573 DIRs submitted by Autocar and Navistar, Meritor decided to file this DIR in accordance with 49.C.F.R. 573.3(f). Meritor is not aware of any accidents or injuries related to this condition. Description of Remedy : Description of Remedy Program : Meritor will work with affected vehicle manufacturers to replace suspect tie rod clamps on the subject axles. Customers are being notified to make arrangements for new replacement tie rod clamps to be installed at no cost. How Remedy Component Differs from Recalled Component : Replacement tie rod clamps will meet Meritor’s specifications for heat treatment. Identify How/When Recall Condition was Corrected in Production : Information released from Meritor: The sub-supplier to Meritor’s tier 1 supplier introduced metallurgical evaluation for excessive carburization for all heat treatment batches and an alarm was installed to alert operator if any deviating conditions occur. The correction was completed 5/11/2022. Recall Schedule : Part 573 Safety Recall Report 22V-879 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Recall Schedule : Notification letters are being sent to customers between 11/30/2022-12/30/2022. Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NOV 30, 2022 – DEC 30, 2022 * NR – Not Reported

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**IMPORTANT SAFETY RECALL*** NHTSA ID: 22V879 November 30, 2022 Dear Alexis Fire Equipment Customer: This notice is sent to you as an Alexis Dealer in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Alexis Fire Equipment has decided that a defect relating to motor vehicle safety exists in certain fire apparatus built on Spartan chassis. Fire apparatus built on Spartan Gladiator, MetroStar, and FC-94 that were manufactured between 2021 – 2023 contain a tie rod clamp defect that may be susceptible to cracking and failure of the part. In response the tie rod clamp supplier, Meritor is issuing a NHTSA Recall No.: 22E-085 / Manufacturer Recall No.: C22AJ. Using information provided by Spartan Fire, LLC. we have located customers in your assigned Alexis territory owning Spartan chassis with the identified defect. The National Traffic and Motor Vehicle Safety Act requires that each vehicle, which is subject to a recall campaign of this type, must be satisfactorily repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within 60 days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. To avoid providing these problematic solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. Vehicle owners are being notified of this recall. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration. APPARATUS VIN: AFE Warranty # AFE Build # Customer VIN # W2477B 2477 Palma-Briensburg 4S9CU2D9XNC560853 REASON FOR THIS RECALL Spartan Fire, LLC. has issued a notice that certain Gladiator, Metro Star, and FC-94 chassis manufactured 2021 through 2023 contain a defective tie rod clamp provided by their supplier, Meritor. Based upon information provided by Meritor’s supplier, due to a heat treat issue, Meritor has determined that a population of tie rod clamps used in the manufacture of the subject axle population may be susceptible to cracking. Over time, a crack may lead to a complete fracture of the clamp, thereby reducing clamp load to the tie rod end. If both clamps on the tie rod were to fail, the cross tube could start to unscrew, vehicle alignment issues would evolve, and there is a potential for the tie rod end to separate from the cross tube. Separation is more likely to occur when tie rod loads are highest, which is at slow vehicle speeds over rough terrain or turning maneuvers. This defect could result in separation of the tie rod end from the cross tube and could result in partial loss of vehicle steering capability, increasing the risk of a crash. The initial effect would be a vehicle out of alignment. If both clamps on the tie rod cracked, the tube could rotate and result in a partial loss of steering capability. REPAIR PROCEDURE: Alexis Fire Equipment will be notifying customers owning products with the identified defect and assisting customers in scheduling a time to have the tie rod clamp replaced at no cost. We will be supplying dealers work instructions and parts to perform the recall. DEALER CAMPAIGN RESPONSIBILITY Dealers are to provide to all customers/owner vehicles the service of completing this campaign at no charge to the customer/owner regardless of vehicle age, vehicle mileage, or ownership at the time of repair. If you should have any questions please contact Alexis Fire Equipment at 1-800-322-2284. Alexis Fire Equipment is taking this action in the interest of safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter. Thank you for your cooperation, Alexis Fire Equipment Company

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