Damaged Brake Line May Leak Brake Fluid – 2023 Horton Emergency Vehicles

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-120
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Halcore Group, Inc. FEB 19, 2024 NHTSA Recall No. : 24V-120 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Halcore Group, Inc.
Address : 3800 McDowell Road
Grove City OH 43123 Company phone : 999
Population :
Number of potentially involved : 34 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2023-2023 Horton Emergency Vehicles Ford F450/F550/F600 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Ford MY23 F450/F550/F600 vehicles fitted by HEV and AEV with a MY22 F-series LiquidSpring (LS) rear suspension kit can have an interference condition between the left rear factory steel brake line and the strut mount.
Production Dates : AUG 21, 2023 – JAN 24, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : On certain REV Ambulance Group Ford MY23 F450/F550/F600 chassis fitted with LS rear suspension kits, the left rear Ford factory steel brake line can come into contact with the strut mount when the LS rear suspension is lowered, potentially wearing a hole in the Ford factory brake line.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : The left rear steel brake line can get a hole worn in the line causing a loss of fluid resulting in brake loss which increases the risk of injury should the brakes fail to engage.
Description of the Cause : Failure to install the modified brake line and/or brackets in the LiquidSpring (LS) kit. There are two causes: 1- the MY22 LS kit was installed on the MY23 chassis, or 2- a MY23 LS kit was installed but the new components were not used due to Halcore operator error. Identification of Any Warning
that can Occur : Brake pedal sponginess and/or brake fluid leak by the rear driver side brake g areas. Part 573 Safety Recall Report 24V-120 Page 2 Involved Components : Component Name 1 : Brake Line Component Description : Brake Line Component Part Number : NR Supplier Identification : Component Manufacturer
Name : LiquidSpring Address : 4899 E 400 S
Lafayette Indiana 47905
Country : United States Chronology :
01/24/24- While a vehicle was on a lift after standard end of production road test, an associate noticed a brake line making contact with LS parts.
01/24- Parts were inspected to validate the correct LS kit was installed. It was determined a MY22 F-series LS kit was installed on a MY23 chassis. MY23 requires a new part to accommodate changes to the parking brake on MY23 units, which the MY22 kit didn’t have.
01/24- MY23 LS kits were inspected to see if the required parts are included, it was determined MY23 LS kits have correct parts.
01/24- Stop ship issued on non-delivered units at HEV. Immediate containment to verify effected units at plant. 01/25 AM- HEV leadership reached out to REV Compliance to notify them of the issue.
01/25- Issue raised to other REV ambulance BUs. It was determined that AEV may also be affected. 01/25- Quality stand down held with chassis team to discuss the issue and ensure awareness/training.
01/25- Investigation into delivered units with incorrect parts installed is initiated. Total population found to be 31 at Horton and 4 at AEV, based on install dates.
01/25- Verification of units starts, working from delivery back to cell 1. Repairs started.
01/26- HEV leadership meets to discuss the issue, response, and next steps. Drafting of DIR begins. 02/16- REV Leadership approved the DIR and a decision file a recall was made. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-120
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : An authorized REV/HEV Dealer or Service Center will need to perform the
remedy.
If the brake line is identified as the Original OEM MY23 Brake Line, the brake line and bracketry must be replaced with the Replacement Brake Line and associated bracketry. Follow modification instructions outlined below for installation of the Replacement Brake Line and associated bracketry for securing the E-brake wiring. Technicians will be provided with technical instructions by REV/HEV to inspect and perform the needed repair.
REV will notify owners and dealers of the campaign. The repairs will be made free of charge. REV will reimburse dealers or owners that have previously paid for a repair that is within the scope of this defect under recall upon presentation of a paid receipt.
Owners will still need to have this recall inspected and/or performed to ensure the correct parts and procedures were utilized. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Modified brake line and brackets will be included in the parts kit. Part numbers from LS are the same for MY22 and MY23, the only differentiator is the Revision #. Horton is tracking the Revision # change and verified which kits in inventory lacked the correct MY23 parts. Required parts ordered to make sure all kits going to MY23 chassis had required parts.
Vehicles affected at the production plant were remedied with the modified parts that came from the supplier in a kit. Retraining held with staff on how to install required components for MY23 chassis and how to identify which kit is correct for a MY23 chassis.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 19, 2024 – MAR 19, 2024
Planned Owner Notification Date : MAR 19, 2024 – APR 19, 2024
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-120
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Halcore Group, Inc. MAR 14, 2024 NHTSA Recall No. : 24V-120 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Halcore Group, Inc.
Address : 3800 McDowell Road
Grove City OH 43123 Company phone : 999
Population :
Number of potentially involved : 34 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2023-2024 Horton Emergency Vehicles Ford F450/F550/F600 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Ford MY23 F450/F550/F600 vehicles fitted by HEV and AEV with a MY22 F-series LiquidSpring (LS) rear suspension kit can have an interference condition between the left rear factory steel brake line and the strut mount.
Production Dates : AUG 21, 2023 – JAN 24, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : On certain REV Ambulance Group Ford MY23-24 F450/F550/F600 chassis fitted with LS rear suspension kits, the left rear Ford factory steel brake line can come into contact with the strut mount when the LS rear suspension is lowered, potentially wearing a hole in the Ford factory brake line.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : The left rear steel brake line can get a hole worn in the line causing a loss of fluid resulting in brake loss which increases the risk of injury should the brakes fail to engage.
Description of the Cause : Failure to install the modified brake line and/or brackets in the LiquidSpring (LS) kit. There are two causes: 1- the MY22 LS kit was installed on the MY23-24 chassis, or 2- a MY23-24 LS kit was installed but the new components were not used due to Halcore operator error. Identification of Any Warning
that can Occur : Brake pedal sponginess and/or brake fluid leak by the rear driver side brake g areas. Part 573 Safety Recall Report 24V-120 Page 2 Involved Components : Component Name 1 : Brake Line Component Description : Brake Line Component Part Number : NR Supplier Identification : Component Manufacturer
Name : LiquidSpring Address : 4899 E 400 S
Lafayette Indiana 47905
Country : United States Chronology :
01/24/24- While a vehicle was on a lift after standard end of production road test, an associate noticed a brake line making contact with LS parts.
01/24- Parts were inspected to validate the correct LS kit was installed. It was determined a MY22 F-series LS kit was installed on a MY23-24 chassis. MY23-24 requires a new part to accommodate changes to the parking brake on MY23-24 units, which the MY22 kit didn’t have.
01/24- MY23-24 LS kits were inspected to see if the required parts are included, it was determined MY23-24 LS kits have correct parts.
01/24- Stop ship issued on non-delivered units at HEV. Immediate containment to verify effected units at plant. 01/25 AM- HEV leadership reached out to REV Compliance to notify them of the issue.
01/25- Issue raised to other REV ambulance BUs. It was determined that AEV may also be affected. 01/25- Quality stand down held with chassis team to discuss the issue and ensure awareness/training.
01/25- Investigation into delivered units with incorrect parts installed is initiated. Total population found to be 31 at Horton and 4 at AEV, based on install dates.
01/25- Verification of units starts, working from delivery back to cell 1. Repairs started.
01/26- HEV leadership meets to discuss the issue, response, and next steps. Drafting of DIR begins. 02/16- REV Leadership approved the DIR and a decision file a recall was made. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-120
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : An authorized REV/HEV Dealer or Service Center will need to perform the
remedy.
If the brake line is identified as the Original OEM MY23-24 Brake Line, the brake line and bracketry must be replaced with the Replacement Brake Line and associated bracketry. Follow modification instructions outlined below for installation of the Replacement Brake Line and associated bracketry for securing the E-brake wiring. Technicians will be provided with technical instructions by REV/HEV to inspect and perform the needed repair.
REV will notify owners and dealers of the campaign. The repairs will be made free of charge. REV will reimburse dealers or owners that have previously paid for a repair that is within the scope of this defect under recall upon presentation of a paid receipt.
Owners will still need to have this recall inspected and/or performed to ensure the correct parts and procedures were utilized. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Modified brake line and brackets will be included in the parts kit. Part numbers from LS are the same for MY22 and MY23-24, the only differentiator is the Revision #. Horton is tracking the Revision # change and verified which kits in inventory lacked the correct MY23-24 parts.
Required parts ordered to make sure all kits going to MY23-24 chassis had required parts.
Vehicles affected at the production plant were remedied with the modified parts that came from the supplier in a kit. Retraining held with staff on how to install required components for MY23-24 chassis and how to identify which kit is correct for a MY23-24 chassis.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : FEB 19, 2024 – MAR 19, 2024
Planned Owner Notification Date : MAR 19, 2024 – APR 19, 2024
* NR – Not Reported

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