February 24, 2023 NHTSA CAMPAIGN NUMBER: 23V124000
Failure of a lower control arm can result in a loss of vehicle control, increasing the risk of a crash.
NHTSA Campaign Number: 23V124
Manufacturer Gillig
, LLC
Components SUSPENSION
Potential Number of Units Affected 349
Summary
GILLIG, LLC (GILLIG) is recalling certain 2011-2021 Low Floor 29-foot CNG transit buses. The rear suspension lower control arm may fail.
Remedy
The remedy is currently under development. As an interim action, Gillig will replace the lower control arm with a new one of the same design, free of charge. Interim notification letters were mailed April 21, 2023. A second letter will be mailed once the final remedy is available, anticipated by the end of 4th Quarter 2023. Owners may contact Gillig 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.
Chronology of Defect / Noncompliance Determination
In late March 2022, GILLIG was notified of a failed lower control arm (LCA) at a transit agency customer location, customer A. GILLIG communicated this information to its supplier, SAF Holland (the “supplier”).
In late April 2022, after a replacement LCA became available, GILLIG sent the failed LCA to the supplier for analysis, but in late June 2022, GILLIG was informed by the supplier that the LCA was lost while in transit to a third party laboratory and no analysis on the field part could be performed.
In late June 2022, GILLIG, and subsequently the supplier, were notified of a second failed LCA arm, the second failure at the same transit agency customer A. The following week, GILLIG quality, engineering, and customer care along with the supplier visited the customer location to inspect the vehicle and learn more about the duty cycle and operations at this customer location.
After this second customer visit, it was decided in early July that a more in-depth analysis of the LCA loading experienced during vehicle operation on route was required to understand if the loading was unique to the vehicle duty cycle at this customer location. A test plan was formulated, instrumentation acquired and the supplier’s team, with GILLIG observing, executed the data collection at customer A location at the end of July.
In early August 2022, after conducting further research, GILLIG found a report of an apparent LCA failure and investigation that occurred in April 2018, customer B. At the time the incident was initially reviewed in 2018, the supplier’s analysis indicated this event to be an anomaly.
Also, in August, the supplier provided preliminary inspection results for LCA #2 from Customer A. The supplier confirmed that although the bar pin bushing appeared to be worn, there had been no metal-to-metal contact between the bar pin and the LCA bore, thus eliminating the possibility of a resulting high-stress concentration in this area.
Postprocessing and analysis of the data collected at customer A location from July 2022 had been in process and in late August, the supplier shared a preliminary assessment and high-level summary with GILLIG that the data indicated the strain profiles were not outside the normal range of other applications where the LCA was used. Based on this feedback, it was decided that a suspension level rig test was needed to accurately capture strain response in the fracture site and validate the supplier’s preliminary assessment.
In late August, GILLIG’s aftermarket parts division was contacted by customer C that communicated that it had two, previously unreported, failures of this control arm. This new information was communicated to the supplier. The LCA’s were discarded by customer C before GILLIG could have them returned for analysis.
In September, the supplier shared with GILLIG the metallurgical results for failed LCA #2 from Customer A and the supplier began looking into potential casting foundry process issues with the control arm manufacturer.
In October, GILLG’s aftermarket parts division received a request for parts to replace a failed LCA from Customer D. The LCA was returned to the supplier for analysis to evaluate whether the request was related to the ongoing issue being investigated. A second LCA replacement part was ordered by this customer in December 2022.
In December, the supplier completed the assembly of the suspension level test-rig initiated in August. With the test rig operational, the supplier was now able to accurately capture the strain response in the fracture site and use this data to better understand the strain profile over specific duty cycles.
In January 2023, the supplier began component level testing on the current design level LCA to enable correlating failure cycles to FEA for fatigue analysis and life predictions. Component level testing was selected over full rig testing to accelerate the data collection.
In February 2023, information was first provided from the supplier to GILLIG that an exceedance of the suspension design limits in a CNG bus application with a high center of gravity contributed to high levels of cumulative strain damage in the LCA.
GILLIG made the decision to conduct a safety recall on February 16, 2023. GILLIG is not aware of any crashes or injuries potentially related to this condition.
End-of-document
11 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| GILLIG | LOW FLOOR 29 FOOT | 2011-2021 |
7 Associated Documents
Defect Notice 573 Report
RCLRPT-23V124-8937.PDF 215.569KB
Recall Acknowledgement
RCAK-23V124-6220.pdf 732.153KB
Chronology
RMISC-23V124-0920.pdf 82.586KB
Interim Owner Notification Letter(Part 577)
RIONL-23V124-8977.pdf 89.041KB
Manufacturer Reimbursement Plan
RMRP-23V124-1009.pdf 180.234KB
Recall 573 Report – 06/14/2023
RCLRPT-23V124-3698.PDF 215.639KB
Recall 573 Report-Amendment 1 – 06/14/2023
RCLRPT-23V124-3799.PDF 215.639KB
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SEOCONTENT-START
GILLIG’s pre-noficaon reimbursement plan
Pursuant to 49 CFR 573.6(c)(8)(i), GILLIG will reimburse owners for costs incurred for remedies in advance of the manufacturer’s noficaon of the safety defect. This pre-noficaon cost reimbursement plan was created in accordance with 49 CFR 573.13.
The beginning date of the period of pre-noficaon reimbursement is 02/24/2022 i.e. one year before the date of the defect noficaon submited by GILLIG to NHTSA on 02/24/2023.
The ending date of the pre-noficaon reimbursement plan will be on 05/01/2023 i.e. 10 calendar days aer the date GILLIG mailed the last of its noficaons to the affected owners.
The plan excludes reimbursement for costs incurred within the period during which GILLIG’s original or extended warranty would have provided for a free repair of the problem addressed by the recall, without any payment by the vehicle owner.
The plan excludes reimbursement in the following circumstances:
(A) If the pre-notification remedy was not of the same type or reasonably equivalent as the recall remedy.
(B) If the pre-notification remedy was not reasonably necessary to correct the defect or noncompliance that led to the recall or a manifestation of the defect or noncompliance.
The following documentation is required to obtain reimbursement of the pre-notification costs:
– Name and mailing address of the vehicle owner.
– Vehicle make, model, model year and VIN.
– The recall campaign number.
– A receipt for the pre-notification remedy performed that identifies the defective control arm and states the total amount paid for the replacement arm.
All claim requests should be directed to field-service@GILLIG.com.
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IMPORTANT SAFETY RECALL
April 21, 2023
GILLIG Campaign ID Number: 23V-124
This notice applies to your vehicle(s) [insert VINs]
<Name>
<Title>
<Property>
<Address>
<City>, <State> <ZIP>
Attn: <Name>
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
GILLIG has decided a defect, which relates to motor vehicle safety, exists in certain model year 2011 through 2021 Low-Floor 29’ CNG transit buses, manufactured between 02/28/2011 and 11/19/2021. These buses contain a lower rear suspension control arm that may, over time, experience fatigue failure. If the lower rear suspension control arm fails, this may cause unintended rear axle movement which could lead to degraded or a loss of vehicle control 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 vehicles that may be affected by the issue. The recall campaign also includes a limited number of defective control arms that were sold by GILLIG’s Aftermarket Parts business and installed on Low-Floor 29’ CNG transit buses.
What The Issue Is:
What GILLIG Will Do
For You:
Low-Floor 29’ CNG transit buses may experience fatigue failure of the rear suspension lower control arm.
1. GILLIG, along with its supplier, is currently developing a permanent remedy for this issue.
2. In the meantime, as an interim remedy, the lower control arm of the affected vehicles should be replaced with a new lower control arm of the existing design.
3. You will receive a second notification to inform you when the permanent remedy is available. The permanent remedy will also be available to customers that received an interim remedy.
4. GILLIG will provide you with the lower control arm and detailed instructions on how to perform the interim and the permanent repairs. Parts and instructions will be provided free of charge.
5. GILLIG will pay a reasonable warranty claim for performing this function. GILLIG estimates a maximum time of 30 min. per vehicle required to perform this function.
We regret any inconvenience that this situation may cause you. GILLIG wants to assure you that we are concerned about customer safety and your continued satisfaction with our products.
Sincerely,
Victor Doran
Executive Director, Quality & Service
CC: Mr. Greg Vismara, V.P., Engineering, GILLIG LLC
Mr. Marco Genova, Product Safety & Compliance Manager, GILLIG LLC
What We Are Asking
You To Do:
1. On your Model Year 2011 to 2021 29’ CNG buses affected by this recall, GILLIG is asking you to implement the interim remedy described above. Please contact GILLG Service at field-service@GILLIG.com.to request the interim remedy parts.
2. When you receive the second notification stating the permanent remedy is available, GILLIG is asking you to follow the instructions to implement the permanent remedy. Additional instructions will be provided to you at that time.
3. If you have already performed this repair, you are eligible to receive reimbursement for the cost of performing the pre-notification repair of the issue that is subject of this recall.
Any questions regarding the information should be directed to GILLIG Service at 1-510-264-5073 (or toll free at 1-800-735-1500) on weekdays between 5:00 AM and 1:30 PM Pacific Time.
If after having attempted to take advantage of this recall you believe you have not been able to have your bus remedied without charge and within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, D.C., 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
Federal regulations require that any vehicle lessor receiving the recall notice must forward a copy of this notice to the vehicle lessee within ten days.
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-124
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Gillig, LLC FEB 24, 2023 NHTSA Recall No. : 23V-124 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Gillig, LLC
Address : 451 Discovery Drive
LIVERMORE CA 94551
Company phone : 1-800-735-1500
Population :
Number of potentially involved : 349 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2011-2021 GILLIG LOW FLOOR 29 foot Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : CNG/LPG
Descriptive Information : Fatigue failure of the rear suspension control arm. The vehicle population being recalled consists of 29-foot low-floor transit buses equipped with a CNG powertrain and with the subject rear suspension lower control arm as either original equipment or a replacement part. Buses equipped with powertrain types other than CNG are not susceptible to the condition.
Production Dates : FEB 28, 2011 – NOV 19, 2021 VIN Range 1 : Begin : 15GGE2714B1092262 End : 15GGE311XM3094152 ✔ Not sequential Description of Defect :
Description of the Defect : GILLIG has determined that the rear suspension lower control arm in 29 foot transit buses configured with a CNG powertrain may experience high levels of cumulative strain damage in some duty cycles and that over time and with increased mileage, the lower control arm may fail.
As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign for the vehicle population that may be affected by the issue. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the lower control arm fails, this could lead to unintended rear axle
movement which could lead to degraded or a loss of vehicle control and increase the risk of a crash. Description of the Cause : NR Part 573 Safety Recall Report 23V-124 Page 2 Identification of Any Warning
that can Occur : GILLIG is not aware of any driver warning prior to component failure. Involved Components : Component Name 1 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-68004-000 (suspension kit) Component Name 2 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-73137-000 (suspension kit) Supplier Identification : Component Manufacturer
Name : SAF Holland
Address : 1950 Industrial Blvd.
Muskegon Michigan 49442 Country : United States Chronology :
The chronology is provided in a separate document. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-124
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : The supplier is developing a permanent remedy for this condition. As an
interim remedy, the lower control arm will be replaced with a new lower control arm of the existing design. Design and validation efforts are underway for a permanent remedy. All customers will be notified when the permanent remedy is available, and the permanent remedy will be also available to customers that received an interim remedy. Both interim and permanent remedies will be provided free of charge. Pursuant to 49 CFR Sec. 573.13, GILLIG will reimburse owners for costs incurred for remedies in advance of the manufacturer’s notification of the safety- related defect. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The interim remedy is the same design as that originally installed at the OEM. When the permanent remedy is complete, the LCA will be of a different design that meets the durability requirements specific for this application.
The recall condition is not present in current production buses. The last units using the parts at issue were produced in November 2021 and the SAF ADZ suspension is no longer an available offering in a GILLIG bus. Recall Schedule :
Description of Recall Schedule : GILLIG plans to send out the owner’s notification letters by the end of the
60-day period from the date this recall is filed. GILLIG does not have a dealer network and, therefore, a dealer’s notification is not required.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : APR 14, 2023 – APR 14, 2023
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-124
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Gillig, LLC JUN 14, 2023 NHTSA Recall No. : 23V-124 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Gillig, LLC
Address : 451 Discovery Drive
LIVERMORE CA 94551
Company phone : 1-800-735-1500
Population :
Number of potentially involved : 435 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2011-2022 GILLIG LOW FLOOR 29 foot Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : CNG/LPG
Descriptive Information : Fatigue failure of the rear suspension control arm. The vehicle population being recalled consists of 29-foot low-floor transit buses equipped with a CNG, hybrid and certain battery electric powertrains and with the subject rear suspension lower control arm as either original equipment or a replacement part. Buses equipped with powertrain types other than the ones indicated, are not susceptible to the condition.
Production Dates : FEB 28, 2011 – JAN 20, 2022 VIN Range 1 : Begin : 15GGE2714B1092262 End : 15GGE3013N3094142 ✔ Not sequential Description of Defect :
Description of the Defect : GILLIG has determined that the rear suspension lower control arm in 29 foot transit buses configured with CNG, Diesel hybrid and certain battery electric powertrains may experience high levels of cumulative strain damage in some duty cycles and that over time and with increased mileage, the lower control arm may fail.
As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign for the vehicle population that may be affected by the issue. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the lower control arm fails, this could lead to unintended rear axle
movement which could lead to degraded or a loss of vehicle control and increase the risk of a crash. Description of the Cause : NR Part 573 Safety Recall Report 23V-124 Page 2 Identification of Any Warning
that can Occur : GILLIG is not aware of any driver warning prior to component failure. Involved Components : Component Name 1 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-68004-000 (suspension kit) Component Name 2 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-73137-000 (suspension kit) Supplier Identification : Component Manufacturer
Name : SAF Holland
Address : 1950 Industrial Blvd.
Muskegon Michigan 49442 Country : United States Chronology :
The chronology is provided in a separate document. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-124
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : The supplier is developing a permanent remedy for this condition. As an
interim remedy, the lower control arm will be replaced with a new lower control arm of the existing design. Design and validation efforts are underway for a permanent remedy. All customers will be notified when the permanent remedy is available, and the permanent remedy will be also available to customers that received an interim remedy. Both interim and permanent remedies will be provided free of charge. Pursuant to 49 CFR Sec. 573.13, GILLIG will reimburse owners for costs incurred for remedies in advance of the manufacturer’s notification of the safety- related defect. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The interim remedy is the same design as that originally installed at the OEM. When the permanent remedy is complete, the LCA will be of a different design that meets the durability requirements specific for this application.
The recall condition is not present in current production buses. The last units using the parts at issue were produced in January 2022 and the SAF ADZ suspension is no longer an available offering in a GILLIG bus. Recall Schedule :
Description of Recall Schedule : GILLIG plans to send out the owner’s notification letters by the end of the
60-day period from the date this recall is filed. GILLIG does not have a dealer network and, therefore, a dealer’s notification is not required.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : APR 14, 2023 – APR 14, 2023
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-124
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Gillig, LLC JUN 14, 2023 NHTSA Recall No. : 23V-124 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Gillig, LLC
Address : 451 Discovery Drive
LIVERMORE CA 94551
Company phone : 1-800-735-1500
Population :
Number of potentially involved : 435 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2011-2022 GILLIG LOW FLOOR 29 foot Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : CNG/LPG
Descriptive Information : Fatigue failure of the rear suspension control arm. The vehicle population being recalled consists of 29-foot low-floor transit buses equipped with a CNG, hybrid and certain battery electric powertrains and with the subject rear suspension lower control arm as either original equipment or a replacement part. Buses equipped with powertrain types other than the ones indicated, are not susceptible to the condition.
Production Dates : FEB 28, 2011 – JAN 20, 2022 VIN Range 1 : Begin : 15GGE2714B1092262 End : 15GGE3013N3094142 ✔ Not sequential Description of Defect :
Description of the Defect : GILLIG has determined that the rear suspension lower control arm in 29 foot transit buses configured with CNG, Diesel hybrid and certain battery electric powertrains may experience high levels of cumulative strain damage in some duty cycles and that over time and with increased mileage, the lower control arm may fail.
As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign for the vehicle population that may be affected by the issue. FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the lower control arm fails, this could lead to unintended rear axle
movement which could lead to degraded or a loss of vehicle control and increase the risk of a crash. Description of the Cause : NR Part 573 Safety Recall Report 23V-124 Page 2 Identification of Any Warning
that can Occur : GILLIG is not aware of any driver warning prior to component failure. Involved Components : Component Name 1 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-68004-000 (suspension kit) Component Name 2 : Lower control arm
Component Description : Lower control arm of the rear suspension Component Part Number : 11-73137-000 (suspension kit) Supplier Identification : Component Manufacturer
Name : SAF Holland
Address : 1950 Industrial Blvd.
Muskegon Michigan 49442 Country : United States Chronology :
The chronology is provided in a separate document. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-124
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : The supplier is developing a permanent remedy for this condition. As an
interim remedy, the lower control arm will be replaced with a new lower control arm of the existing design. Design and validation efforts are underway for a permanent remedy. All customers will be notified when the permanent remedy is available, and the permanent remedy will be also available to customers that received an interim remedy. Both interim and permanent remedies will be provided free of charge. Pursuant to 49 CFR Sec. 573.13, GILLIG will reimburse owners for costs incurred for remedies in advance of the manufacturer’s notification of the safety- related defect. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The interim remedy is the same design as that originally installed at the OEM. When the permanent remedy is complete, the LCA will be of a different design that meets the durability requirements specific for this application.
The recall condition is not present in current production buses. The last units using the parts at issue were produced in January 2022 and the SAF ADZ suspension is no longer an available offering in a GILLIG bus. Recall Schedule :
Description of Recall Schedule : GILLIG plans to send out the owner’s notification letters by the end of the
60-day period from the date this recall is filed. GILLIG does not have a dealer network and, therefore, a dealer’s notification is not required.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : APR 14, 2023 – APR 14, 2023
* NR – Not Reported