October 4, 2023 NHTSA CAMPAIGN NUMBER: 23V678000
Warning Light Malfunction/FMVSS 105
Failure to illuminate the indicator warning lights during vehicle startup may not properly notify the driver of system failures, increasing the risk of a crash.
NHTSA Campaign Number: 23V678
Manufacturer Lightning eMotors Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 239
Summary
Lightning eMotors Inc. (Lightning eMotors) is recalling certain 2021-2022 FT3-40, 2021-2023 FT3-80, and 2022-2023 FT3-120 vehicles. The instrument cluster may not activate the “Brake,” “Park,” and “ABS” indicator warning lights during the light function check when the ignition is turned to the “on” (run) position. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 105, “Hydraulic and Electric Brake Systems.”
Remedy
Dealers will update the software, free of charge. Owner notification letters are expected to be mailed December 1, 2023. Owners may contact Lightning eMotors customer service at 1-970-744-7241.
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 :
June 27, 2023: Vehicle testing of unrelated software upgrades indicated a potential issue with the instrument cluster display
June 27 – August 2, 2023: The issue was evaluated by the technical team
August – September, 2023: The issue was referred to the Legal Department for evaluation of potentially affected regulatory requirements; legal/regulatory evaluation was performed
September 18, 2023: Based upon the technical and regulatory evaluation, the issue was escalated to the Lighting eMotors Recall Committee
September 27, 2023: The Recall Committee determined that the issue constitutes an FMVSS noncompliance
October 4, 2023: Part 573 Report filed
October 5, 2023: NHTSA rejected the Part 573 filing; requested to re-file with revised safety risk description.
October 9, 2023: Revised Part 573 report filed.
7 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| LIGHTNING EMOTORS | FT3-120 | 2022-2023 |
| LIGHTNING EMOTORS | FT3-40 | 2021-2022 |
| LIGHTNING EMOTORS | FT3-80 | 2021-2023 |
2 Associated Documents
Noncompliance Notice 573 Report
RCLRPT-23V678-5239.PDF 214.887KB
Recall Acknowledgement
RCAK-23V678-9290.pdf 646.079KB
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-678 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Lightning eMotors Inc. Submission Date : OCT 09, 2023 NHTSA Recall No. : 23V-678 Manufacturer Recall No. : NR 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 : 239 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Lightning eMotors FT3-40 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID
ELECTRIC Descriptive Information : The instrument cluster on the subject vehicles may not activate the BRAKE, PARK and ABS indicator lamps during the lamp function check when the ignition is turned to the “on” (run) position. The recall scope was determined by a review of production records. Production Dates : JAN 01, 2021 – DEC 31, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2021-2023 Lightning eMotors FT3-80 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID
ELECTRIC Descriptive Information : The instrument cluster on the subject vehicles may not activate the BRAKE, PARK and ABS indicator lamps during the lamp function check when the ignition is turned to the “on” (run) position. The recall scope was determined by a review of production records. Production Dates : JAN 01, 2021 – OCT 01, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-678 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 3 : 2022-2023 Lightning eMotors FT3-120 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID
ELECTRIC Descriptive Information : The instrument cluster on the subject vehicles may not activate the BRAKE, PARK and ABS indicator lamps during the lamp function check when the ignition is turned to the “on” (run) position. The recall scope was determined by a review of production records. Production Dates : JAN 01, 2022 – OCT 01, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : The subject vehicles may not meet the “check of lamp” requirements of FMVSS 105 S5.3.2(a). FMVSS 1 : 105 – Hydraulic and electric brake systems FMVSS 2 : NR Description of the Safety Risk : The indicator lamps will illuminate correctly to indicate the presence of the conditions or malfunctions specified in FMVSS 105 S5.3.1. However, the driver may be unaware if the indicator lamps were to become inoperable. If one or more of the indicator lamps were to fail, the driver would not be notified of the issue, increasing the risk of a crash. Description of the Cause : A software update inadvertently affected the “check of lamp” functionality. Identification of Any Warning that can Occur : The operator might notice the indicator lamps not illuminating when the ignition switch is turned to the “on” position during the bulb check sequence. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer Name : Lightning eMotors Part 573 Safety Recall Report 23V-678 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Address : NR NR Country : NR Chronology : June 27, 2023: Vehicle testing of unrelated software upgrades indicated a potential issue with the instrument cluster display June 27 – August 2, 2023: The issue was evaluated by the technical team August – September, 2023: The issue was referred to the Legal Department for evaluation of potentially affected regulatory requirements; legal/regulatory evaluation was performed September 18, 2023: Based upon the technical and regulatory evaluation, the issue was escalated to the Lighting eMotors Recall Committee September 27, 2023: The Recall Committee determined that the issue constitutes an FMVSS noncompliance October 4, 2023: Part 573 Report filed October 5, 2023: NHTSA rejected the Part 573 filing; requested to re-file with revised safety risk description. October 9, 2023: Revised Part 573 report filed. Description of Remedy : Description of Remedy Program : Owners will be advised of the availability of a software update (Versions 3.1.0 or 3.1.1) that will address the issue. The required update will be provided free of charge. How Remedy Component Differs from Recalled Component : Updated software (Versions 3.1.0 or 3.1.1) will address this issue. Identify How/When Recall Condition was Corrected in Production : To be provided Recall Schedule : Description of Recall Schedule : Customers will be notified on or before the dates set forth in the Planned Notification section. Planned Dealer Notification Date : DEC 01, 2023 – DEC 01, 2023 Planned Owner Notification Date : DEC 01, 2023 – DEC 01, 2023 * NR – Not Reported
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