R23-20 – Transmission May Separate from Driveshaft – 2019-2024 New Flyer XD35, XD40, XN35, & XN40 Transit Buses

SEOCONTENT-START

OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-722 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : New Flyer of America, Inc. Submission Date : OCT 26, 2023 NHTSA Recall No. : 23V-722 Manufacturer Recall No. : R23-20 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 : 2,351 Estimated percentage with defect : 25 % Vehicle Information : Vehicle 1 : 2019-2024 New Flyer XD35, XD40, XN35, XN40 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR Descriptive Information : This recall is based on an Allison Transmission, Inc. (ATI) recall issued under 23E079. The population was determined based on ATI’s serial number (SN) list provided to New Flyer. Products included are New Flyer buses produced with an Allison B400R or B3400xFE_R transmission. Buses without those transmissions are not included. Production Dates : JAN 14, 2019 – OCT 20, 2023 VIN Range 1 : Begin : 2FYD8FV16KC054372 End : 5FYD8FV03RF108452 ✔ Not sequential Description of Defect : Description of the Defect : Under certain conditions, the output yoke bolt may loosen and potentially result in separation of the driveline from the transmission output shaft. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the driveline separates from the transmission output shaft while driving, the vehicle may experience an unexpected loss of motive power, which may increase the risk of a crash. Description of the Cause : ATI has not yet determined the cause of the loosening of the output yoke bolt. Transit bus duty cycles have a very high start/stop shift density. This generates significantly more torsional activity on this bolted joint than other applications. Testing by ATI and its customer is ongoing. Identification of Any Warning that can Occur : The failure could occur with warning. Part 573 Safety Recall Report 23V-722 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Involved Components : Component Name 1 : TRANSMISSION Component Description : TRANSMISSION-B400R Component Part Number : 351260 Component Name 2 : TRANSMISSION Component Description : TRANSMISSION-B3400XFE_R Component Part Number : 620070 Component Name 3 : TRANSMISSION Component Description : TRANSMISSION-B3400XFE_R W/COOLER Component Part Number : 811430 Component Name 4 : TRANSMISSION Component Description : TRANSMISSION-B400R GEN 5 Component Part Number : 874200 Component Name 5 : TRANSMISSION Component Description : TRANSMISSION-B3400XFE_R Component Part Number : 919377 Component Name 6 : TRANSMISSION Component Description : TRANSMISSION-B400R TC421 GEN 6 Component Part Number : 967874 Component Name 7 : TRANSMISSION Component Description : TRANSMISSION-B400R TC418 GEN 6 Component Part Number : 967879 Part 573 Safety Recall Report 23V-722 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 8 : TRANSMISSION Component Description : TRANSMISSION-B3400XFER TC421 GEN 6 Component Part Number : 1019263 Component Name 9 : TRANSMISSION Component Description : TRANSMISSION-B400R TC421 GEN 6 W/ COOLER NY Component Part Number : 1011646NY Component Name 10 : TRANSMISSION Component Description : TRANSMISSION-B400R W/COOLER Component Part Number : 513887NY Component Name 11 : TRANSMISSION Component Description : TRANSMISSION-B400R W/COOLER NY Component Part Number : 875514NY Supplier Identification : Component Manufacturer Name : Allison Transmission, Inc. Address : Mail Code M23 One Allison Way Indianapolis Indiana 46222-3271 Country : United States Chronology : New Flyer investigated reports of loose transmission yokes from a US based property, and in July/August 2023 requested the transmission supplier (Allison Transmission, Inc [ATI]) assist and review. August/September, 2023, through checks that ATI performed on the subject buses, a higher-than-expected number of fasteners holding the yoke to the transmission output shaft were identified. New Flyer and ATI continued discussions surrounding the cause, which led to ATI issuing an equipment recall (NHTSA, 23E079). New Flyer was made aware of this recall on October 17, 2023, and held several conference Part 573 Safety Recall Report 23V-722 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 calls with Allison for additional details. A review of the issue and ATI’s recall were the basis of a special meeting of New Flyer’s Safety Committee on October 23, 2023, and consensus determined New Flyer would issue a recall, culminating in this submission. Description of Remedy : Description of Remedy Program : New Flyer and/or ATI will coordinate with customers to make arrangements for ATI to inspect the output yoke bolts and, if necessary, tighten loose output yoke bolts. This will be performed at no charge to the customer. If a customer requires to perform the work themself, New Flyer will reimburse through our normal warranty process. How Remedy Component Differs from Recalled Component : ATI increased the torque specification for the output yoke bolt for all B400R and B3400xFE_R transmissions. The clamp load for the output yoke bolt was increased by approximately 150%, nominal torque is being increased from the previous specification of 77.5 Newton-meters (Nm) to 130 Nm. Identify How/When Recall Condition was Corrected in Production : Upon receiving notice from ATI on the recall, New Flyer stopped shipping affected buses until ATI personnel had entered our production plants and addressed the fasteners to the new torque spec. Recall Schedule : Description of Recall Schedule : New Flyer and ATI are jointly determining which entity will notify customers (end-users). Once determined, a draft notification letter will be submitted no less than 5 days prior to issuing – either under this recall, or under 23E079. Please note New Flyer does not have a dealer network – dates are aligned with our owner notification dates. Planned Dealer Notification Date : NOV 30, 2023 – NOV 30, 2023 Planned Owner Notification Date : NOV 30, 2023 – NOV 30, 2023 * NR – Not Reported

**************************************************************************************************************

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 ITS60844 19-Oct-2023 SECTION: 219-Engine and Transmission WRITTEN BY: Mike Pearson SUBJECT: Retorque Transmission Yoke as per Allison Document SIL 20-WT-23 ISSUE: This is to inform you that your vehicle may be non-compliant with the requirements of the Motor Vehicle Safety Regulations and that the noncompliance could affect the safety of a person. Allison Transmission has observed a potential concern that affects the output shaft yoke/flange retaining bolt SUMMARY: As a Customer Satisfaction Initiative, Allison will support increasing the output shaft yoke/flange retaining bolt torque specification for B3400 R xFE™ and B400 R Series transmissions. ITS60844 Ref. NHTSA Recall No. Ref. Transport Canada Recall No. 23V722 TC 2023-575 INSTRUCTION TO SERVICE ITS60844 ITS60844 Page 2 of 5 19-Oct-2023 PROCEDURE: 1. Set park brake and chock wheels. 2. Turn the main battery disconnect switch to the “OFF” position. 3. Retorque the transmission yoke bolts per the following Allison Field Action Letter SIL 20-WT-23. INSTRUCTION TO SERVICE ITS60844 ITS60844 Page 3 of 5 19-Oct-2023 INSTRUCTION TO SERVICE ITS60844 ITS60844 Page 4 of 5 19-Oct-2023 INSTRUCTION TO SERVICE ITS60844 ITS60844 Page 5 of 5 19-Oct-2023 4. Remove all tools and debris from work area to return coach to service. 5. Turn the main battery disconnect switch to the “ON” position. LABOUR ESTIMATE Operation Number of Technician(s) Hours Labor Time T X HR 1 Retorque Transmission Yoke as per Allison Document SIL 20-WT-23 1 1.0 As Required PARTS REQUIRED Item Part Number Description Qty. per Coach Units Notes 1 N/A All parts supplied by Allison 1 EA

**************************************************************************************************************

**************************************************************************************************************

SEOCONTENT-END