March 27, 2023 NHTSA CAMPAIGN NUMBER: 23V207000
Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
NHTSA Campaign Number: 23V207000
Manufacturer Lightning eMotors Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 148
Summary
Lightning eMotors Inc. (Lightning) is recalling certain 2020 FE4-86 and FT3-43, 2019-2021 FE4-129, and 2019-2022 FT3-86 vehicles. The battery packs
may have defective structural welds and experience an internal radiator leak, causing battery failure.
Remedy
Lightning will replace the battery pack, free of charge. Owner notification letters were mailed May 31, 2023. Owners may contact Lightning customer service at 1-970-744-7241. Lightning’s number for this recall is 2023-001.
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.
Lightning eMotors, Inc. (“LeM”) has decided that a defect which relates to motor vehicle safety exists in certain Model Year 2020 FT3-43 and FE4-86, Model Year 2019-2021 FE4-129, and Model Year 2019 – 2022 FT3-86 vehicles equipped with eMatrix Energy Systems battery packs. This action involves vehicles in which LeM powertrains were installed from January 1, 2020, through February 2, 2022, and which use eMatrix Energy Systems battery packs. Our records indicate that your vehicle(s) listed above may be affected.
What is the Problem?
Defective structural welds and internal radiator leaks have been found in the eMatrix battery packs installed in these vehicles. These conditions may result in isolation faults and cell imbalances that may cause a loss of traction drive, which may increase the risk of a crash, or thermal runaway, which may increase the risk of a fire.
What Are We Doing About the Problem?
LeM will replace the eMatrix batteries with a non-defective battery, free of charge. If a replacement battery is unavailable, LeM will discuss alternative remedy options with you. Please contact LeM at [email protected] or 970-744-4926 for more information.
Chronology :
11/14/2021 – A thermal event occurred in a FT3-86 model equipped with an eMatrix battery
11/15/2021 – An investigation into the cause of the thermal event was initiated with the battery supplier (eMatrix)
4/27/2022 – The battery supplier and experts had their first opportunity to inspect the FT3-86, and the vehicle’s batteries were removed
6/17/2022 – The FT3-86 vehicle was released from the insurance company to Lightning for testing and analysis
6/2022 – Lightning commenced inspections of welds on suspect eMatrix batteries to assist in identifying potential root cause(s) of the thermal event
9/20/2022 – A thermal event was reported on an FE4-129, and a second root cause investigation was initiated
9/26/2022 – Lightning commenced daily monitoring of telematics data for indicators of potential eMatrix battery defects
10/4/2022 – Lightning disassembled two eMatrix battery packs and found coolant leaking from an internal radiator
12/2022 – The insurer of the FT3-86 vehicle released its report opining that a failed support structure of the battery caused the thermal event
1/6/2023 – Lightning engaged a weld expert who opined that the welding of the support structure of all eMatrix battery models was inadequate for the intended purpose
1/20/2023 – Lightning prepared a root cause analysis report with the radiator and/or the inadequate welds and substructure as likely cause(s) of the thermal events
2/10/2023 – Lightning’s engineering report was presented to the battery supplier for review and discussion (eMatrix did not undertake or assist in the investigation or analysis)
3/17/2023 – Lightning held a follow-up meeting with the supplier to discuss the findings
3/21/2023 – Lightning’s Recall Committee decided to conduct a recall
To date, there have been no accidents or injuries related to this condition.
9 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| LIGHTNING EMOTORS | FE4-129 | 2019-2021 |
| LIGHTNING EMOTORS | FE4-86 | 2020 |
| LIGHTNING EMOTORS | FT3-43 | 2020 |
| LIGHTNING EMOTORS | FT3-86 | 2019-2022 |
8 Associated Documents
Recall Acknowledgement
RCAK-23V207-5169.pdf 646.702KB
Defect Notice 573 Report
RCLRPT-23V207-2590.PDF 215.08KB
Recall 573 Report-Amendment 1 – 04/07/2023
RCLRPT-23V207-6196.PDF 215.994KB
Recall 573 Report-Amendment 2 – 04/21/2023
RCLRPT-23V207-8150.PDF 216.032KB
ISSUED Owner Notification Letter(Part 577) – Redacted
RCONL-23V207-8316.pdf 152.565KB
Recall Quarterly Report #1, 2023-2
RCLQRT-23V207-3060.PDF 211.136KB
Recall 573 Report-Amendment 3 – 10/16/2023
RCLRPT-23V207-3127.PDF 216.265KB
Recall Quarterly Report #2, 2023-3
RCLQRT-23V207-4764.PDF 211.372KB
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SEOCONTENT-START
815 14th St SW, Suite A100
Loveland, CO 80537, USA
800.223.0740
lightningemotors.com
[email protected]
[email protected]
*** IMPORTANT SAFETY RECALL ***
NHTSA Recall No. 23V-207
This notice applies to your vehicle:
Bus Model Vehicle Identification Number (VIN)
E-450
May 31, 2023
Dear Lightning eMotors Customer:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Lightning eMotors, Inc. (“LeM”) has decided that a defect which relates to motor vehicle safety exists in
certain Model Year 2020 FT3-43 and FE4-86, Model Year 2019-2021 FE4-129, and Model Year 2019
– 2022 FT3-86 vehicles equipped with eMatrix Energy Systems battery packs. This action involves
vehicles in which LeM powertrains were installed from January 1, 2020, through February 2, 2022, and
which use eMatrix Energy Systems battery packs. Our records indicate that your vehicle(s) listed above
may be affected.
What is the Problem?
Defective structural welds and internal radiator leaks have been found in the eMatrix battery packs
installed in these vehicles. These conditions may result in isolation faults and cell imbalances that may
cause a loss of traction drive, which may increase the risk of a crash, or thermal runaway, which may
increase the risk of a fire.
What Are We Doing About the Problem?
LeM will replace the eMatrix batteries with a non-defective battery, free of charge. If a replacement
battery is unavailable, LeM will discuss alternative remedy options with you. Please contact LeM at
[email protected] or 970-744-4926 for more information.
Page 2
815 14th St SW, Suite A100
Loveland, CO 80537, USA
Telephone: 1.800.223.0740
lightningemotors.com
If you no longer own the vehicle(s) listed above, please forward this notice to the new owner and provide
the new owner’s address to us at [email protected].
Federal law requires vehicle lessors receiving this recall notice to forward a copy to the lessee within ten
days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle covered by this recall
notice under a sale or lease until the noncompliance has been remedied.
Questions or Concerns?
If you have questions or concerns about this recall, please contact us at [email protected]
or 970-744-4926. If you are unable to obtain a remedy without charge within a reasonable time, you
may submit a complaint to: Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Avenue, SE, Washington, DC 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.
We are taking this action in the interest of your safety and satisfaction with our products. We apologize
for any inconvenience and thank you for your attention to this matter.
Sincerely,
Ben Schroder
Ben Schroder
Director, Field Customer Service
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-207
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lightning eMotors Inc. APR 21, 2023 NHTSA Recall No. : 23V-207 Manufacturer Recall No. : 2023-001 Manufacturer Information :
Manufacturer Name : Lightning eMotors Inc.
Address : 815 14th Street SW
Suite A100 Loveland CO 80537 Company phone : (970)744-7241
Population :
Number of potentially involved : 148 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2020-2020 Lightning eMotors FT3-43 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 9 vehicles.
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2019-2021 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 40 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-207 Page 2 Vehicle 3 : 2020-2020 Lightning eMotors FE4-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 6 vehicles
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2019-2022 Lightning eMotors FT3-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 93 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Defective structural welds and internal radiator leaks have been found in the battery packs of this population of vehicles. Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Defective structural welds and internal radiator leaks could result in failure of traction drive increasing the potential for collisions, and thermal runaway of Traction Batteries which could result in vehicle fires.
Description of the Cause : Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances. Identification of Any Warning
that can Occur : None Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207 Page 3 Component Name 1 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M35E Component Part Number : 811-09 Component Name 2 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M36 Component Part Number : 811-010 Component Name 3 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; LG MH1 cells; MH-1 Component Part Number : 811-011 Component Name 4 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 42.6KWh; 375V; M48 Component Part Number : 811-012 Supplier Identification : Component Manufacturer
Name : eMatrix Address : 21520 Bridge St
Southfield Michigan 48033
Country : United States Chronology :
11/14/2021 – A thermal event occurred in a FT3-86 model equipped with an eMatrix battery 11/15/2021 – An investigation into the cause of the thermal event was initiated with the battery supplier (eMatrix)
4/27/2022 – The battery supplier and experts had their first opportunity to inspect the FT3-86, and the vehicle’s batteries were removed
6/17/2022 – The FT3-86 vehicle was released from the insurance company to Lightning for testing and analysis
6/2022 – Lightning commenced inspections of welds on suspect eMatrix batteries to assist in identifying The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
potential root cause(s) of the thermal event
9/20/2022 – A thermal event was reported on an FE4-129, and a second root cause investigation was initiated 9/26/2022 – Lightning commenced daily monitoring of telematics data for indicators of potential eMatrix battery defects
10/4/2022 – Lightning disassembled two eMatrix battery packs and found coolant leaking from an internal radiator
12/2022 – The insurer of the FT3-86 vehicle released its report opining that a failed support structure of the battery caused the thermal event
1/6/2023 – Lightning engaged a weld expert who opined that the welding of the support structure of all eMatrix battery models was inadequate for the intended purpose
1/20/2023 – Lightning prepared a root cause analysis report with the radiator and/or the inadequate welds and substructure as likely cause(s) of the thermal events
2/10/2023 – Lightning’s engineering report was presented to the battery supplier for review and discussion (eMatrix did not undertake or assist in the investigation or analysis)
3/17/2023 – Lightning held a follow-up meeting with the supplier to discuss the findings 3/21/2023 – Lightning’s Recall Committee decided to conduct a recall
To date, there have been no accidents or injuries related to this condition.
Description of Remedy :
Description of Remedy Program : Remedy Program is under development at this time. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Remedy Program is under development at this time. eMatrix Battery Packs were removed from production by design in early MY2022. Recall Schedule :
Description of Recall Schedule : Recall notification schedule is under development at this time.
Planned Dealer Notification Date : APR 28, 2023 – APR 28, 2023
Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-207
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lightning eMotors Inc. APR 07, 2023 NHTSA Recall No. : 23V-207 Manufacturer Recall No. : 2023-001 Manufacturer Information :
Manufacturer Name : Lightning eMotors Inc.
Address : 815 14th Street SW
Suite A100 Loveland CO 80537 Company phone : (970)744-7241
Population :
Number of potentially involved : 148 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2020-2020 Lightning eMotors FT3-43 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 9 vehicles.
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2019-2022 Lightning eMotors FT3-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 93 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-207 Page 2 Vehicle 3 : 2020-2020 Lightning eMotors FE4-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 6 vehicles
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2019-2021 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 40 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Defective structural welds and internal radiator leaks have been found in the battery packs of this population of vehicles. Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Defective structural welds and internal radiator leaks could result in failure of traction drive increasing the potential for collisions, and thermal runaway of Traction Batteries which could result in vehicle fires.
Description of the Cause : Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances. Identification of Any Warning
that can Occur : None Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207 Page 3 Component Name 1 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M35E Component Part Number : 811-09 Component Name 2 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M36 Component Part Number : 811-010 Component Name 3 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; LG MH1 cells; MH-1 Component Part Number : 811-011 Component Name 4 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 42.6KWh; 375V; M48 Component Part Number : 811-012 Supplier Identification : Component Manufacturer
Name : eMatrix Address : 21520 Bridge St
Southfield Michigan 48033
Country : United States Chronology :
11/14/2021 – A thermal event occurred in a FT3-86 model equipped with an eMatrix battery 11/15/2021 – An investigation into the cause of the thermal event was initiated with the battery supplier (eMatrix)
4/27/2022 – The battery supplier and experts had their first opportunity to inspect the FT3-86, and the vehicle’s batteries were removed
6/17/2022 – The FT3-86 vehicle was released from the insurance company to Lightning for testing and analysis
6/2022 – Lightning commenced inspections of welds on suspect eMatrix batteries to assist in identifying The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
potential root cause(s) of the thermal event
9/20/2022 – A thermal event was reported on an FE4-129, and a second root cause investigation was initiated 9/26/2022 – Lightning commenced daily monitoring of telematics data for indicators of potential eMatrix battery defects
10/4/2022 – Lightning disassembled two eMatrix battery packs and found coolant leaking from an internal radiator
12/2022 – The insurer of the FT3-86 vehicle released its report opining that a failed support structure of the battery caused the thermal event
1/6/2023 – Lightning engaged a weld expert who opined that the welding of the support structure of all eMatrix battery models was inadequate for the intended purpose
1/20/2023 – Lightning prepared a root cause analysis report with the radiator and/or the inadequate welds and substructure as likely cause(s) of the thermal events
2/10/2023 – Lightning’s engineering report was presented to the battery supplier for review and discussion (eMatrix did not undertake or assist in the investigation or analysis)
3/17/2023 – Lightning held a follow-up meeting with the supplier to discuss the findings 3/21/2023 – Lightning’s Recall Committee decided to conduct a recall
To date, there have been no accidents or injuries related to this condition.
Description of Remedy :
Description of Remedy Program : Remedy Program is under development at this time. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Remedy Program is under development at this time. eMatrix Battery Packs were removed from production by design in early MY2022. Recall Schedule :
Description of Recall Schedule : Recall notification schedule is under development at this time.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-207
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lightning eMotors Inc. OCT 16, 2023 NHTSA Recall No. : 23V-207 Manufacturer Recall No. : 2023-001 Manufacturer Information :
Manufacturer Name : Lightning eMotors Inc.
Address : 815 14th Street SW
Suite A100 Loveland CO 80537 Company phone : (970)744-7241
Population :
Number of potentially involved : 148 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2020-2020 Lightning eMotors FT3-43 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 9 vehicles.
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2019-2022 Lightning eMotors FT3-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 93 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-207 Page 2 Vehicle 3 : 2020-2020 Lightning eMotors FE4-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 6 vehicles
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2019-2021 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 40 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Defective structural welds and internal radiator leaks have been found in the battery packs of this population of vehicles. Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Defective structural welds and internal radiator leaks could result in failure of traction drive increasing the potential for collisions, and thermal runaway of Traction Batteries which could result in vehicle fires.
Description of the Cause : Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances. Identification of Any Warning
that can Occur : None Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207 Page 3 Component Name 1 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M35E Component Part Number : 811-09 Component Name 2 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M36 Component Part Number : 811-010 Component Name 3 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; LG MH1 cells; MH-1 Component Part Number : 811-011 Component Name 4 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 42.6KWh; 375V; M48 Component Part Number : 811-012 Supplier Identification : Component Manufacturer
Name : eMatrix Address : 21520 Bridge St
Southfield Michigan 48033
Country : United States Chronology :
11/14/2021 – A thermal event occurred in a FT3-86 model equipped with an eMatrix battery 11/15/2021 – An investigation into the cause of the thermal event was initiated with the battery supplier (eMatrix)
4/27/2022 – The battery supplier and experts had their first opportunity to inspect the FT3-86, and the vehicle’s batteries were removed
6/17/2022 – The FT3-86 vehicle was released from the insurance company to Lightning for testing and analysis
6/2022 – Lightning commenced inspections of welds on suspect eMatrix batteries to assist in identifying The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207
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The information contained in this report was submitted pursuant to 49 CFR §573
potential root cause(s) of the thermal event
9/20/2022 – A thermal event was reported on an FE4-129, and a second root cause investigation was initiated 9/26/2022 – Lightning commenced daily monitoring of telematics data for indicators of potential eMatrix battery defects
10/4/2022 – Lightning disassembled two eMatrix battery packs and found coolant leaking from an internal radiator
12/2022 – The insurer of the FT3-86 vehicle released its report opining that a failed support structure of the battery caused the thermal event
1/6/2023 – Lightning engaged a weld expert who opined that the welding of the support structure of all eMatrix battery models was inadequate for the intended purpose
1/20/2023 – Lightning prepared a root cause analysis report with the radiator and/or the inadequate welds and substructure as likely cause(s) of the thermal events
2/10/2023 – Lightning’s engineering report was presented to the battery supplier for review and discussion (eMatrix did not undertake or assist in the investigation or analysis)
3/17/2023 – Lightning held a follow-up meeting with the supplier to discuss the findings 3/21/2023 – Lightning’s Recall Committee decided to conduct a recall
To date, there have been no accidents or injuries related to this condition.
Description of Remedy :
Description of Remedy Program : Remedy Program is under development at this time. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Remedy Program is under development at this time. eMatrix Battery Packs were removed from production by design in early MY2022. Recall Schedule :
Description of Recall Schedule : There are no affected dealers, so LeM will not be issuing a dealer
notification. Accordingly, there is no “Dealer Notification” schedule. Owners were notified in accordance with the “Planned Owner Notification” dates. Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : JUN 02, 2023 – JUN 02, 2023
* NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-207
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lightning eMotors Inc. MAR 27, 2023 NHTSA Recall No. : 23V-207 Manufacturer Recall No. : 2023-001 Manufacturer Information :
Manufacturer Name : Lightning eMotors Inc.
Address : 815 14th Street SW
Suite A100 Loveland CO 80537 Company phone : (970)744-7241
Population :
Number of potentially involved : 148 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2020-2020 Lightning eMotors FT3-43 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 9 vehicles.
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2019-2022 Lightning eMotors FT3-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 93 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-207 Page 2 Vehicle 3 : 2020-2020 Lightning eMotors FE4-86 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 6 vehicles
Production Dates : JAN 01, 2020 – DEC 31, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2019-2021 Lightning eMotors FE4-129 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : HYBRID ELECTRIC
Descriptive Information : All Lightning eMotors vehicles equipped with eMatrix Battery Packs are affected. Vehicles not affected by this recall are equipped with Proterra or Romeo Battery Packs. This recall affects 40 vehicles.
Production Dates : JAN 01, 2019 – FEB 01, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : Defective structural welds and internal radiator leaks have been found in the battery packs of this population of vehicles. Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Defective structural welds and internal radiator leaks could result in failure of traction drive increasing the potential for collisions, and thermal runaway of Traction Batteries which could result in vehicle fires.
Description of the Cause : Structural failure or internal coolant leaks of an eMatrix battery may result in isolation faults and cell imbalances. Identification of Any Warning
that can Occur : None Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207 Page 3 Component Name 1 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M35E Component Part Number : 811-09 Component Name 2 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 43.2KWh; 352V; M36 Component Part Number : 811-010 Component Name 3 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; LG MH1 cells; MH-1 Component Part Number : 811-011 Component Name 4 : Traction Battery, eMatrix
Component Description : TRACTION BATTERY; Ematrix; 42.6KWh; 375V; M48 Component Part Number : 811-012 Supplier Identification : Component Manufacturer
Name : eMatrix Address : 21520 Bridge St
Southfield Michigan 48033
Country : United States Chronology :
To be provided. Description of Remedy : Description of Remedy Program : Remedy Program is under development at this time. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-207
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
Remedy Program is under development at this time. eMatrix Battery Packs were removed from production by design in early MY2022. Recall Schedule :
Description of Recall Schedule : Recall notification schedule is under development at this time.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR
* NR – Not Reported
SEOCONTENT-END
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