24508 – Brake Lights May Fail to Illuminate – 2024-2025 IC Bus CE School Buses

May 29, 2024 NHTSA CAMPAIGN NUMBER: 24V375000

NHTSA Campaign Number: 24V375

Manufacturer Navistar, Inc.

Components EXTERIOR LIGHTING

Potential Number of Units Affected 319

Summary

Navistar, Inc. (Navistar) is recalling certain 2024-2025 IC Bus CE school buses. The brake lights, in certain conditions, may not illuminate when the brake pedal is depressed, due to a software error. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 121, “Air Brake Systems.”

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-375
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. MAY 28, 2024 NHTSA Recall No. : 24V-375 Manufacturer Recall No. : 24508 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 319 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2024-2025 IC Bus CE SBUS
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The inclusive dates of manufacture were determined by the date vehicles were built with an incorrect software feature code and when Navistar contained the issue in manufacturing. The vehicles in the suspect population were built with an incorrect feature code and all other similar vehicles were not.
Production Dates : JAN 05, 2023 – MAY 02, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : • When the pressure in one of the air brake circuits is completely drained, with pressure maintained in the other air circuit, the stop lamps do not activate when the brake pedal is depressed.
• Buses do not conform to Federal Motor Vehicle Safety Standard (FMVSS) 121; Air Brake Systems:
o S5.1 Required equipment for trucks and buses. Each truck and bus shall have the following equipment:
o S5.7.1 Service Brake Stop Lamp Switch. A switch that lights the stop lamps when the service brake control is statically depressed to a point that produces a pressure of 6 psi or less in the service brake chambers. FMVSS 1 : 121 – Air brake systems FMVSS 2 : NR
Description of the Safety Risk : • Stop lamps that do not conform to all the requirements of FMVSS 121 may not illuminate when the driver depresses the brake pedal.
• This may not alert other motorists that the bus is slowing, which can Part 573 Safety Recall Report 24V-375 Page 2 increase the risk of a vehicle crash that may result in property damage or injury.
Description of the Cause : A software configuration rule to support a change to the air brake pressure monitoring system hardware was not properly implemented. Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : NR Component Description : Software Component Part Number : NR Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
05/07/2024 – An IC Bus dealer informed Navistar that the stop lamps did not activate when the brake pedal was depressed. It was confirmed that when pressure in one of the air brake circuits is completely drained, with pressure maintained in the other air circuit, the stop lamps will not illuminate when the brake pedal is depressed.
05/09/2024 thru 05/22/2024 Navistar initiates a ship hold of 266 units located at its Tulsa Bus Plant. 05/13/2024 – Navistar Product Safety and R&D meet to review the failure mode, potential suspect units and discuss next steps.
05/14/2024 – Navistar Product Safety and R&D meet to review vehicles that are on ship hold and the progress to identify the remaining suspect units at the assembly plant and in the field.
05/16/2024 – Navistar R&D and Service Engineering developed a repair strategy and began repairing suspect units at the assembly plant.
05/22/2024 – Navistar R&D and Product Safety finalize the suspect population. 05/23/2024 – Navistar declares a Noncomplaince Recall. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-375
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : • The remedy will involve programming the correct software
configuration into the bus.
• Navistar’s plan for reimbursement of pre-notification remedies, on file with NHTSA and dated 05/06/2022, applies and reimbursement instructions will be included in the customer notification. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The remedy software configuration aligns with installed hardware to read both air brake circuit pressures, illuminating the stop lamps when either circuit detects the driver depressing the brake pedal.
Rules that implement software configurations during order processing were corrected on 5/14/2024 Recall Schedule :
Description of Recall Schedule : Dealers will be notified first thru Navistar’s Service Portal. Owner
notification mailing will begin one week later.
Planned Dealer Notification Date : JUL 08, 2024 – JUL 08, 2024
Planned Owner Notification Date : JUL 15, 2024 – JUL 15, 2024
* NR – Not Reported

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