R22-035 Upper Steering Shaft Connection May Loosen – 2013-2022 New Flyer XDE35, XDE40, XDE60, XE40, XN40, 2017-2022 XE60, 2014-2022 XT40 & XT60 Transit Buses

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-943 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : New Flyer of America, Inc. Submission Date : DEC 20, 2022 NHTSA Recall No. : 22V-943 Manufacturer Recall No. : R22-035 Manufacturer Information : Manufacturer Name : New Flyer of America, Inc. Address : 711 Kernaghan Avenue Winnipeg, MB 00 R2C3T4 Company phone : 204-224-6706 Population : Number of potentially involved : 746 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2013-2022 New Flyer XDE35, XDE40, XDE60, XE40, XE60, XN40, XT40, XT60 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR Descriptive Information : Recall population was based on vehicles using a specific, non-standard steering column, which is a “double tilt” column, allowing a normal tilt function, as well as a function to allow the entire column to pivot away from the dash. Product is isolated to specific customers that require this column type Production Dates : NOV 18, 2013 – DEC 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On certain buses, the steering column to upper steering shaft connection may become loose over time FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the steering column and/or steering shaft become loose and worn, loss of steering may occur. Loss of steering increases the risk of a crash. At this time, zero reports of steering loss have been reported Description of the Cause : The torque value on the pinch bolt which clamps the upper steering shaft collar to the column was lower than necessary Identification of Any Warning that can Occur : A “clicking” sound was reported coming from the lower steering column area while turning prior to identifying the issue Part 573 Safety Recall Report 22V-943 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Steering column Component Description : COLUMN-STEERING DBL TILT 9204 Component Part Number : 536446 Component Name 2 : Upper steering shaft Component Description : JOINT-U STRG DBL TILT Component Part Number : 532703 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : In late November 2022, a customer indicated a “clicking” sound was heard from a steering column November 29, 2022, our Service Representative met with the customer and reviewed the bus in question Over the ensuing days, several more buses were checked, culminating in a fleet check on or about December 06, 2022, which indicated an issue with the upper steering shaft clamping collar to column connection In early December, New Flyer assembled a team to analyze the issue and determine the cause. This team focused on spline engagement, torque value of the pinch-bolt used on the collar of the steering shaft-to-column connection, and steering components The team ultimately determined the pinch bolt torque was lower than necessary New Flyer’s Safety Committee met on December 16, 2022, and determined a Safety Recall was warranted, and New Flyer subsequently submitted the recall Part 573 Safety Recall Report 22V-943 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : New Flyer will check, with appropriate gauges, and replace necessary steering column and shaft components, and re-torque affected pinch bolts. In the event material supply becomes a constraint, there are secondary plans to permanently attach the column-to-shaft connection through welding of the components How Remedy Component Differs from Recalled Component : Once components are replaced or verified, the additional torque application to the pinch bolt would prevent further issues. If the secondary plans are executed, the permanent attachment would also prevent further issues. Identify How/When Recall Condition was Corrected in Production : When the torque was identified as suspect, engineering release a change notice to require the torque increase. The change release was implemented on affected buses in our manufacturing plants, prior to customer delivery Recall Schedule : Description of Recall Schedule : A draft recall letter will be provided for review, and owner letters will be issued within approx. 3 weeks of NHTSA approval of the draft, but not more than 60 days after this recall submission. Please note as New Flyer does not have a dealer network, dates entered are simply to line up with customer notification Planned Dealer Notification Date : FEB 13, 2023 – FEB 17, 2023 Planned Owner Notification Date : FEB 13, 2023 – FEB 17, 2023 * NR – Not Reported

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THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND MAINTENANCE STAFF GOING FORWARD. This document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and the contents herein are not to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure, reproduction or other distribution of this document or information strictly prohibited and may result in action being taken against the party making the unauthorized disclosure. This document and all copies hereof must be returned to New Flyer upon request. INSTRUCTION TO SERVICE ITS: 60596 December 21, 2022 SECTION: 350-Driver’s Controls WRITTEN BY: Troy Stutsky SUBJECT: Movement in Steering Column to Upper Steering Drive Shaft Joint ISSUE: An under torque on the pinch bolt between the steering column & upper steering drive shaft has caused movement and wear in the joint. SUMMARY: Torque existing hardware to specification and inspect joints. Remove the steering column & upper steering drive shaft & replace parts if required. ITS60596 Ref. NHTSA Recall No. Ref. Transport Canada Recall No. 22V-943 2022-732 INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 2 of 9 December 21, 2022  NOTE: Please note, New Flyer will allow the use of a combination of new parts, existing parts and / or welded parts as long as they meet the requirements that are outlined in the procedures written in this document ITS-60596. PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the main battery disconnect switch to the “OFF” position. 3. On the steering assembly of the bus with the steering assembly still installed in the bus, please torque the hardware in the four locations shown in Figure 1 to 70±4Ft/Lbs dry. Please ensure that the bolts are 7/16” – 20 X 2.00”; Grade 8; Zinc (NF PN 6444255) & the nuts are 7/16” – 20; Self Locking; Zinc (NF PN 6444254). If any 10MM hardware is found in any of these four locations it should be removed and replaced. Remove existing torque witness marks and re-mark after new torque has been applied. Figure 1: Locations to Torque on Steering System 1 2 3 4 INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 3 of 9 December 21, 2022 4. After the new torque has been applied, inspect for any free play at the splined, torqued joint between the steering column and the upper steering drive shaft, which is identified as Area #1 in Figure 1, by grasping the drive shaft mid-length and applying a lateral force. There should be no free play in this torqued joint. If no free play has been found, the bus is safe to return to service. 5. If free play is found at the splined, torqued joint between the steering column and the upper steering drive shaft, which is identified as Area #1 in Figure 1, please proceed to remove the steering column & upper steering drive shaft from the bus for closer inspection on the shop bench. 6. With the steering column and the upper steering drive shaft removed from the bus and on the bench, please separate the steering column from the upper steering drive shaft. 7. Using the PSS Go/No Go Plug tool measure the solid, splined end of the upper steering drive shaft. See Figure 2. a. If the Go/No Go Plug will not fit into the splined portion of the drive shaft, the upper steering drive shaft is a pass and can be reused as required. b. If the Go/No Go Plug does fit into the splined portion of the drive shaft, the upper steering drive shaft is a fail and will need to be safely stored for using in a welded assembly if required. Figure 2: Upper Steering Shaft Measurement 8. Using the No Go Gauge measure the splined end of the steering column. See Figure 3. a. If the No Go Gauge will not fit over the splined portion of the steering column, the steering column is a pass and can be reused as required. b. If the No Go Gauge does fit over the splined portion of the steering column, the steering column is a fail and will need to be safely stored for using in a welded assembly if required. Upper Steering Drive Shaft Go/No Go Plug Tool Splines to Measure INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 4 of 9 December 21, 2022 Figure 3: Steering Column Measurement 9. Any combination of new or used parts that are available and that have deemed as a pass using the above Go / No Go measurements can be used to repair the buses. When refastening the verified good upper steering drive shafts to the verified good steering columns please use new hardware bolt 7/16” – 20 X 2.00”; Grade 8; Zinc (NF PN 6444255) & nut 7/16” – 20; Self Locking; Zinc (NF PN 6444254) at the joint between the upper steering drive shaft and the steering shaft shown in Figure 4. Torque the hardware to 70±4Ft/Lbs dry. Remove existing torque witness marks and re-mark after new torque has been applied. 10. Re-install the steering column with upper steering drive shaft back into the bus. Torque the hardware where the upper steering drive shaft fastens to the miter box to 70±4Ft/Lbs dry. Remove existing torque witness marks if required and re-mark after new torque has been applied. The bus is safe to return to service. 11. The steering columns and upper steering drive shafts that were deemed to be failed, as tested by the Go / No Go measurements, may be used together as a welded assembly as required. To weld together one steering column and one upper steering drive shaft, please follow the instructions in Appendix A with welding procedure data sheet provided in Appendix B.  NOTE: When welding the steering colum and the upper drive shaft please place heat sinks next to the steering column bearing, adjacent to the weld area, to prevent the heat from traveling further up the steering column to protect any adjacent components. Copper or aluminum blocks would be great options. No Go Gauge Steering Column Splines to Measure INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 5 of 9 December 21, 2022  NOTE: When pre-heating the steel to 200F before welding, a digital temperature gun or temperature stick rated to 200F should be used.  NOTE: Given that one of the steels being welded is 1141, we request an MPI inspection on the first 10 welded assemblies and if all 10 are OK then complete 1 in 10 for the remainder. 12. When the steering column and upper steering drive shaft welded assy is complete and has passed MPI inspection it can be re-installed in the bus. Torque the hardware where the upper steering drive shaft fastens to the miter box to 70±4Ft/Lbs dry. Remove existing torque witness marks if required and re-mark after new torque has been applied. The bus is safe to return to service. 13. After any procedure has been completed please clean up all tools and debris and return the bus to service condition. 14. Turn the main battery disconnect switch to the “ON” position. INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 6 of 9 December 21, 2022 LABOUR ESTIMATE Operation Number of Technician(s) Hours Labor Time T X HR 1 Torque existing hardware to specification and inspect joints 2 0.5 1.0 2 Remove and replace the steering column & upper steering drive shaft if required 2 1.5 3.0 PARTS REQUIRED Item Part Number Description Qty. per Coach Units Notes 1 536446 COLUMN-STEERING DBL TILT 9204 1 EA If Required 2 6447692 STEERING COLUMN, SERVICE ASSEMBLY 1 EA If Required 3 532703 JOINT-U STRG DBL TILT 1 EA If Required 4 068035 BOOT TAPERED 1.56&4.5ID 1 EA If Required 5 50S00016 SCREW FH CROSS RECESS TPG. TYPE AB #10 X 1″ LG. 4 EA If Required 6 004944 SCREW-TPG CSK 10-32X1.0LG 2 EA If Required 7 6444255 BOLT, HEX 7/16″ – 20 UNF X 2″ LG. 4 EA If Required 8 6444254 NUT, HEX 7/16″ – 20 UNF 4 EA If Required SPECIAL TOOLS REQUIRED Item Part Number Description Qty. Units Notes 1 NPN Welding Wire 0.01 EA If Required 2 NPN Welding Gas 0.01 EA If Required 3 NPN Torque Paint Marker 0.01 EA If Required INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 7 of 9 December 21, 2022 Appendix A INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 8 of 9 December 21, 2022 Appendix A Continued… INSTRUCTION TO SERVICE ITS60596 ITS60596 Page 9 of 9 December 21, 2022 Appendix B

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_________________________________________________________________________________________________________________ TSIB 22-13 Rev. A Page 1 of 1 December 19, 2022 TECHNICAL SERVICE INFORMATION BULLETIN TSIB 22-13 Rev A December 19, 2022 TO: Affected Operators TITLE: Torque value changes to splined joints in the steering system. APPLICABILITY: New Flyer Xcelsior buses equipped with double tilt steering columns. This TSIB will provide an updated recommendation for torque of hardware used to secure the splined joints in in the steering system between the steering column and the gearbox. For customers operating New Flyer Xcelsior buses equipped with double tilt steering columns, it is New Flyer’s recommendation that, at the next maintenance interval, the torque in the four locations depicted in the diagram be increased from 50 ft-lb to 70 ft-lb ± 4 ft-lb. Direct all inquiries regarding this bulletin to: Kevin Robinson, CET Technical Services Manager C 204.430.8826 [email protected] New Flyer

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IMPORTANT SAFETY RECALL NOTICE 01-February-2023 VIA US First Class Mail Sound Transit ATTN: Tim Wagner 401 S Jackson St Seattle, WA 98104 Subject: Motor Vehicle Safety Recall 22V-943 Steering Column/Upper Steering Shaft To whom it may concern: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. New Flyer of America Inc. (New Flyer) has decided that a defect which relates to motor vehicle safety exists on specific vehicles equipped with a “double tilt” steering column. New Flyer has determined that the following vehicles, operated by Sound Transit are affected by this recall action: Make: New Flyer Heavy Duty Urban Transit Bus Model: XDE60 VIN Fleet # Model Model Year 5FYH8YU09LB073879 9660 XDE60 2020 5FYH8YU05LB073880 9661 XDE60 2020 5FYH8YU07LB073881 9662 XDE60 2020 5FYH8YU09LB073882 9663 XDE60 2020 5FYH8YU00LB073883 9664 XDE60 2020 5FYH8YU02LB073884 9665 XDE60 2020 5FYH8YU04LB073885 9666 XDE60 2020 5FYH8YU06LB073886 9667 XDE60 2020 5FYH8YU08LB073887 9668 XDE60 2020 5FYH8YU0XLB073888 9669 XDE60 2020 5FYH8YU01LB073889 9670 XDE60 2020 5FYH8YU08LB073890 9671 XDE60 2020 5FYH8YU0XLB073891 9672 XDE60 2020 5FYH8YU01LB073892 9673 XDE60 2020 5FYH8YU03LB073893 9674 XDE60 2020 5FYH8YU05LB073894 9675 XDE60 2020 5FYH8YU07LB073895 9676 XDE60 2020 5FYH8YU09LB073896 9677 XDE60 2020 5FYH8YU00LB073897 9678 XDE60 2020 5FYH8YU02LB073898 9679 XDE60 2020 VIN Fleet # Model Model Year 5FYH8YU04LB073899 9680 XDE60 2020 5FYH8YU07LB073900 9681 XDE60 2020 5FYH8YU09LB073901 9682 XDE60 2020 5FYH8YU00LB073902 9683 XDE60 2020 5FYH8YU02LB073903 9684 XDE60 2020 5FYH8YU04LB073904 9685 XDE60 2020 5FYH8YU06LB073905 9686 XDE60 2020 5FYH8YU08LB073906 9687 XDE60 2020 5FYH8YU0XLB073907 9688 XDE60 2020 5FYH8YU01LB073908 9689 XDE60 2020 5FYH8YU03LB073909 9690 XDE60 2020 The double-tilt column used in the affected vehicles has been found to have wear between the steering column and upper steering shaft connection. This wear has been determined to be due to a lower than necessary torque value on the pinch bolt of the steering shaft collar. This reduced clamp force from the pinch bolt may allow wear, over time, which may cause the spline engagement between the 2 components to further loosen and allow slipping in the connection. (Preceding potential slippage of the steering components, an audible sound described as a “clicking” may be noticed.) This slipping could cause a loss of steering control. A loss of steering control increases the potential for a vehicle crash and injury. New Flyer will check the steering column and upper steering shaft splines to verify no excessive wear, replace components as necessary, and re-torque the pinch bolt on the steering shaft collar on the above vehicles at no cost. Please contact your Regional Product Support Manager to coordinate the recall action. New Flyer anticipates that the repairs to correct the issue will take approximately 0.5 – 1.5 hours/bus. If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If you no longer own this vehicle, or it has been removed from operation permanently, please inform the undersigned. If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. If New Flyer is unable to correct this defect within a reasonable time, you may submit a written complaint to the: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE, Washington, DC, 20590, Or call 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees. Thank you for your attention to this important matter. Sincerely, NEW FLYER OF AMERICA INC. By: Jim Johnson Vehicle Safety & Regulatory Compliance Manager (256) 453-7181 cc (email): Scott Halbesma – Vice President, Customer Care Kevin Hiemenz – Regional Director Joe Jonak – Regional Product Support Manager

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-943 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : New Flyer of America, Inc. Submission Date : JAN 10, 2023 NHTSA Recall No. : 22V-943 Manufacturer Recall No. : R22-035 Manufacturer Information : Manufacturer Name : New Flyer of America, Inc. Address : 711 Kernaghan Avenue Winnipeg, MB 00 R2C3T4 Company phone : 204-224-6706 Population : Number of potentially involved : 746 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2013-2022 New Flyer XDE35, XDE40, XDE60, XE40, XE60, XN40, XT40, XT60 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR Descriptive Information : Recall population was based on vehicles using a specific, non-standard steering column, which is a “double tilt” column, allowing a normal tilt function, as well as a function to allow the entire column to pivot away from the dash. Product is isolated to specific customers that require this column type Production Dates : NOV 18, 2013 – DEC 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On certain buses, the steering column to upper steering shaft connection may become loose over time FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the steering column and/or steering shaft become loose and worn, loss of steering may occur. Loss of steering increases the risk of a crash. At this time, zero reports of steering loss have been reported Description of the Cause : The torque value on the pinch bolt which clamps the upper steering shaft collar to the column was lower than necessary Identification of Any Warning that can Occur : A “clicking” sound was reported coming from the lower steering column area while turning prior to identifying the issue Part 573 Safety Recall Report 22V-943 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : Steering column Component Description : COLUMN-STEERING DBL TILT 9204 Component Part Number : 536446 Component Name 2 : Upper steering shaft Component Description : JOINT-U STRG DBL TILT Component Part Number : 532703 Supplier Identification : Component Manufacturer Name : Douglas Autotech Coporation Address : 300 Albers Road Bronson Michigan 49028 Country : United States Chronology : In late November 2022, a customer indicated a “clicking” sound was heard from a steering column November 29, 2022, our Service Representative met with the customer and reviewed the bus in question Over the ensuing days, several more buses were checked, culminating in a fleet check on or about December 06, 2022, which indicated an issue with the upper steering shaft clamping collar to column connection In early December, New Flyer assembled a team to analyze the issue and determine the cause. This team focused on spline engagement, torque value of the pinch-bolt used on the collar of the steering shaft-to-column connection, and steering components The team ultimately determined the pinch bolt torque was lower than necessary New Flyer’s Safety Committee met on December 16, 2022, and determined a Safety Recall was warranted, and New Flyer subsequently submitted the recall Part 573 Safety Recall Report 22V-943 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : New Flyer will check, with appropriate gauges, and replace necessary steering column and shaft components, and re-torque affected pinch bolts. In the event material supply becomes a constraint, there are secondary plans to permanently attach the column-to-shaft connection through welding of the components If the owner performs the work, New Flyer will provide replacement parts and reimburse labor costs associated with this correction through our warranty process. In the event a customer has made similar repairs within approx. 12 months prior to this recall, New Flyer will reimburse through our warranty process How Remedy Component Differs from Recalled Component : Once components are replaced or verified, the additional torque application to the pinch bolt would prevent further issues. If the secondary plans are executed, the permanent attachment would also prevent further issues. Identify How/When Recall Condition was Corrected in Production : When the torque was identified as suspect, engineering release a change notice to require the torque increase. The change release was implemented on affected buses in our manufacturing plants, prior to customer delivery Recall Schedule : Description of Recall Schedule : A draft recall letter will be provided for review, and owner letters will be issued within approx. 3 weeks of NHTSA approval of the draft, but not more than 60 days after this recall submission. Please note as New Flyer does not have a dealer network, dates entered are simply to line up with customer notification Planned Dealer Notification Date : FEB 13, 2023 – FEB 17, 2023 Planned Owner Notification Date : FEB 13, 2023 – FEB 17, 2023 * NR – Not Reported

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