August 8, 2023 NHTSA CAMPAIGN NUMBER: 23V560000
An inaccurate fuel gauge may result in the vehicle unexpectedly running out of fuel and stalling, increasing the risk of a crash.
NHTSA Campaign Number: 23V560
Manufacturer Hino Motors Sales U.S.A., Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 8,025
Summary
Hino Motors Sales U.S.A., Inc. (Hino) is recalling certain 2020-2024 NE7A, NE7B, NE8A, NH9A, NJ7A, NJ7B, NJ8A, NJ8J, NV7A, NV7B, and NV8A vehicles equipped with 70 or 90 gallon fuel tanks. The fuel sender float may deform and detach, which can lead to an inaccurate fuel gauge reading.
Remedy
Dealers will replace the fuel sender gauge, free of charge. Owner notification letters are expected to be mailed October 6, 2023. Owners may contact Hino customer service at 1-248-699-9390. Hino’s number for this recall is AAV70.
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 Determination
June – August, 2022
On June 29, Hino started an investigation upon receiving a field report of a vehicle where the fuel gauge showed “Empty” at all times. Hino collected the fuel sender gauge from the subject vehicle and found the fuel sender connecting rod detached from the fuel gauge.
September – December, 2022
Hino inspected its inventory fuel sender gauge and its assembly processes for fuel sender at its West Virginia production facility. There were no abnormalities observed in either its inventory of fuel sender parts or its assembly processes.
January – July, 2023
Due to unknown frequency and effect of the potential fuel sender issue, Hino continued field monitoring. As a result of field monitoring, Hino determined that the issues were concentrated in models equipped with either 70 or 90 gallon fuel tanks. Hino collected suspect fuel sender gauges from field vehicles equipped with 70 or 90 gallon fuel tanks for further investigation.
The investigation revealed the fuel sender connecting rods were deformed. Hino continued a detailed investigation to understand the root cause of fuel sender connecting rod deformation.
Through testing, Hino determined that when an excessive load is applied to the fuel sender connecting rod float installed in 90 gallon fuel tanks, for example due to fuel sloshing during hard braking event, the fuel sender connecting rod deforms and may become disconnected from the fuel sender gauge. In addition, from estimation of fuel sloshing in a 70 gallon fuel tank, Hino determined that vehicles equipped with a 70 gallon tank have the possibility of experiencing the same excessive load on the fuel sender float phenomena, which may result in the fuel sender connecting rod becoming detached. Through field monitoring, Hino has determined that models equipped with a 50 gallon fuel tank have not been experiencing similar issues. Hino also confirmed the load applied to a fuel sender connecting rod float in a 50 gallon tank did not result in sufficient energy to deform the fuel sender connecting rod. Hino then verified that a reduced size and density of the fuel sender connecting rod would reduce the load applied to the fuel sender float and prevent the fuel sender connecting rod from deforming.
On August 1, 2023, based on the above investigation result, Hino determined it would conduct a voluntary safety recall campaign for the subject vehicles equipped with either 70 or 90 gallon fuel tanks.
As of July 31, 2023, Hino is aware of 233 warranty claims for this issue (9 cases of stall or no engine start, 7 cases of reads full but is empty, 73 cases of reads empty but has fuel, and 144 cases that the customer complaint is unclear) related to fuel sender connecting rod deforming and detaching from the fuel sender gauge, and which were repaired from May 9, 2022 to July 17 2023. To date, Hino is not aware of any reports of accidents or injuries related this issue.
5 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| HINO | CONVENTIONAL MODELS | 2020-2024 |
3 Associated Documents
Recall Acknowledgement
RCAK-23V560-9527.pdf 645.352KB
Defect Notice 573 Report
RCLRPT-23V560-6837.PDF 214.014KB
Chronology
RMISC-23V560-5000.pdf 127.239KB
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-560 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Hino Motors Sales U.S.A., Inc. Submission Date : AUG 08, 2023 NHTSA Recall No. : 23V-560 Manufacturer Recall No. : AAV70 Manufacturer Information : Manufacturer Name : Hino Motors Sales U.S.A., Inc. Address : 45501 Twelve Mile Road Novi MI 48377 Company phone : 248-699-9300 Population : Number of potentially involved : 8,025 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2024 Hino NE7A, NE7B, NE8A, NH9A, NJ7A, NJ7B, NJ8A, NJ8J, NV7A, NV7B, NV8A Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : Power Train : DIESEL Descriptive Information : The recall population was determined by reviewing Hino production and sales records for certain vehicle models equipped with 70 or 90 gallon fuel tanks manufactured at Hino’s West Virginia production facility. All Hino models equipped with 70 or 90 gallon fuel tanks manufactured between March 10, 2020 and July 28, 2023 are potentially affected by this issue. Vehicles not included in this recall are either repaired prior to shipment, manufactured after countermeasure was applied on the vehicle production line mentioned below, or equipped with different fuel tank specifications. Production Dates : MAR 10, 2020 – JUL 28, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The fuel sender float connecting rod, which is located inside the fuel tank, may become detached. This may lead to an incorrect fuel level being displayed on the fuel level indicator. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Inaccurate fuel indication may lead to an engine stall due to fuel starvation, increasing the risk of a crash. Description of the Cause : The surface area of the fuel sender float may allow excessive load to be applied to the fuel sender float connecting rod due to fuel sloshing during, for example, Part 573 Safety Recall Report 23V-560 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 a hard braking event. In this condition, the fuel sender float connecting rod may deform and detach from the fuel sender gauge. Identification of Any Warning that can Occur : N/R Involved Components : Component Name 1 : Gauge assy, Fuel Sender Component Description : Fuel Sender Gauge Assembly Component Part Number : 83320-E0381 Supplier Identification : Component Manufacturer Name : YAZAKI Corporation Address : 7th floor, W Building, 1-8-15 Konan Minato-ku Foreign States 108-0075 Country : Japan Chronology : See attached. Description of Remedy : Description of Remedy Program : For all the subject vehicles, a Hino dealer will replace the fuel sender gauge with an improved fuel sender gauge, free of charge. Customers who have received the “Customer Notification Letter for Recall (AAV70)”, who may have paid for repairs due to this defect may apply for reimbursement for those repair costs. All pre-notification reimbursement requests for repairs which were performed until a date 10 days after the final customer notification is made will be considered by Hino for reimbursement. Hino will also reimburse for all Parts, Labor, and miscellaneous costs directly related to the remedy of this defect. Requests for reimbursement, including paid receipts, should be directed to warranty@hino.com. Part 573 Safety Recall Report 23V-560 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : Remedy fuel sender gauges contain a float with less surface area compared with the recall fuel sender gauge, reducing potential force on the float during operation. Identify How/When Recall Condition was Corrected in Production : Improved fuel sender gauge will be applied to Hino’s West Virginia vehicle production line Mid-August, 2023. Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : AUG 09, 2023 – AUG 09, 2023 Planned Owner Notification Date : OCT 06, 2023 – OCT 06, 2023 * NR – Not Reported
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