June 21, 2019 NHTSA CAMPAIGN NUMBER: 19V479000
Excessive Force to Needed Buckle Seat Belts
In the event of a crash, the seat belt may not buckle or properly restrain a passenger in the event of a crash, increasing the risk of an injury.
NHTSA Campaign Number: 19V479
Manufacturer Navistar
, Inc.
Components SEAT BELTS
Potential Number of Units Affected 9
Summary
Navistar, Inc. (Navistar) is recalling certain 2011 IC CE transit buses equipped with certain non-retractable passenger two-point lap belts. After long term buckling and unbuckling of the seat belt, the plastic fingers on the male portion of the buckle may crack and fall off, requiring excessive force to buckle the seat belt.
Remedy
Navistar will notify owners and dealers will replace the seat belt assemblies, free of charge. Navistar issued interim notifications to owners on August 16, 2019. The recall began September 23, 2019. Owners may contact Navistar customer service at 1-800-448-7825.
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.safercar.gov.
NHTSA is missing critical, required information for this safety recall. This information must be supplied through the NHTSA Recalls Portal within 5 working days of confirming its accuracy:
– An identification and description of the risk to motor vehicle safety reasonably related to the defect or noncompliance as described by an increased risk of injury, fire or crash (49 CFR 573.6 (c)(5)).
– A description of the manufacturer’s program for remedying the defect or noncompliance (49 CFR 573.6 (c)(8)(i)).
- 09/11/2018 NHTSA sends communication to Navistar advising that a VOQ had been submitted the agency regarding passenger two-point lap style seat belts in their CE buses.
- 09/12/2018 Navistar starts the investigation on this issue; and contacts the customer to get the detailed information about the VOQ that was submitted to NHTSA.
- 10/3/2018 Interim review of test findings to date which found multiple fractures observed around the radius of the plastic fingers. And that there was a lack of deformation at any of the fracture locations, which indicate a brittle fracture.
- 10/10/2018 Navistar updates NHTSA on the investigation regarding the total potential suspect population that were built with the finger design on the tongue side of the belt.
- 10/17/2018 Navistar performed a local inspection at the Naperville school district in Illinois and inspected 7 buses with approximately 30 belts per bus. Each bus had at least one or more plastic fingers missing on one of the belts, up to 7 belts with one or more broken plastic fingers.
- 10/18/2018 Shield provided a third-party lab report from 2014 which indicated environmental stress cracking caused the plastic finger failures, because of a likely school district cleaning chemical which was not identified in the report. The conclusion in that time frame was that the plastic finger failures on the tongue were maintenance related
- 10/31/2018 Navistar received VIN information from State of New Jersey customer through a local dealer indicating they had 13 buses where several belts had broken plastic fingers on each bus.
- 11/16/2018 Received report from third-party lab on request from Navistar to do environmental testing for root cause. The microscopic examination of the fracture surface features indicate that the ABS material failure is resulting from exposure to high mechanical loads experienced in service both from cyclic fatigue and assembly.
- 1/9/2019 Navistar runs a seat belt tongue durability test. Seat belt buckles tested at 1 and 2 mm displacement passed the minimum cycle count requirement established by Navistar as 50,000 cycles without failure, buckles tested at 3 mm displacement did not meet the required cycle count.
- 1/14/2019 Navistar performs a seat belt strain verses force test. The force and displacement required to achieve the proper strain was much higher than the force and displacement during durability testing. The conclusion was that these force and displacement numbers will not last the required number of cycles (50,000), since we observed failures at an average of 5,586 cycles with a 3 mm oscillating displacement.
- 02/19/2019 Navistar receives PE18-015 from NHTSA
- 02/20/2019 Navistar performs a fit evaluation study with students ranging in age from 6 to 14. Peak strains were also measured.
- 02/20/2019 – 04/01/19 Navistar gathers data and documents to respond to the inquiry.
- 04/02/2019 Navistar submits PE18-015 response to NHTSA indicating that Navistar believes the issue with broken plastic fingers on the seat belt tongue cover for the applicable IC school buses does not pose an unreasonable risk of injury to the seat occupant in a vehicle crash on large school buses because the seating is designed for compartmentalization and is not dependent on the function of a seat belt. Therefore, reported incidents would be handled as a customer satisfaction issue.
- 04/02/2019 Received a test report from Shield after Navistar submitted the PE response. First, they ran a test with a late suspect buckle (C3 version) at typical FMVSS 209 requirements. Then they ran an abuse scenario that applied forces to the tongue without the buckle to allow excessive movement of the fingers at 100% (30lbf), 133% (40lbf) and 200% (60lbf) of the FMVSS 209 force requirement. They indicated that all parts passed 200 cycles of preconditioning [S5.2 (g)] and post-performance testing [S4.2 (g)].
- 04/24/2019 Shield ran a similar test to above with an earlier suspect buckle (C2 version) with similar results to the 4/2/19 test.
- 05/01/2019 Navistar asked NHTSA on status of the investigation and NHTSA indicated they were analyzing the data.
- 05/14/2019 Met with NHTSA ODI. NHTSA disagreed with Navistars conclusions in response to PE18-015. They did share their analysis of the warranty and service part data. NHTSA recommended Navistar consider recalling certain buses.
- 05/20/2019 Navistar met to review NHTSA data analysis. Actions included looking at the warranty failure data from a statistical basis and also reviewing the data from a per belt failure rate basis.
- 05/28/2019 Navistar and NHTSA ODI met again to review the per belt data. There was no change in NHTSA direction because of the high service part usage even with low per belt warranty.
- 06/03/2019 Navistar completed statistical study and discussed NHTSA rationale for performing a recall. Concluded that the 2011 model year buses were statistically different than the other model years.
- 06/10/2019 Navistar and NHTSA reviewed proposal to recall 2011 model year IC buses based on the higher warranty failure rate.
- 06/12/2019 Navistar meets to review the above events. Because the seats in this application meet the compartmentalization requirements of FMVSS 222 without seat belts, agreement was reached to the above proposal pending finalizing the suspect population for the recall and the extending warranty for other model years.
- 06/17/2019 Navistar declares a Safety Recall for 2011 model year IC buses.
SEOCONTENT-START
Public
IC Bus, LLC
2701 Navistar Drive
Lisle, IL 60532 USA
navistar.com
MAILED
SEP 23 2019
Compliance Dept.
A NAV/SliUI COMPANY
IMPORTANT SAFETY RECALL 19511
NHTSA RECALL NO. 19V-479
This notice applies to your vehicle identified on the
enclosed card.
Dear IC Bus Customer,
This notice is sent to you in accordance with the
requirements of the National Traffic and Motor Vehicle
Safety Act.
IC Bus has decided that a defect which relates to motor
vehicle safety exists in certain 2011 CE model commercial
buses built 7 April 2010 thru 11 June 201 O with nonretractable
passenger two-point lap belts by
Amsafe/Shield.
REASON FOR THIS RECALL
Long term cycle fatigue (buckling and unbuckling the seat
belt) may cause the plastic fingers on the male portion of
the buckle to crack and break off resulting in an increase in
force necessary to latch the seat belt buckle.
RISK TO MOTOR VEHICLE SAFETY
All bus seats provide a safe environment regardless of belt
availability. However, in certain crashes, a risk of injury
could be impacted without the ability to properly latch the
belt.
DEFECT REMEDY
The repair will involve replacement of seat belt assemblies
that have not already been replaced with the center push
buckles. Dealers have parts and instructions to repair your
vehicle. The repair will be performed free of charge and
take approximately 45 minutes to 1 hour 30 minutes to
complete.
ACTIONS YOU SHOULD TAKE
If you own this vehicle, please schedule an appointment
with any IC Bus dealer to have your vehicle repaired. You
SEPTEMBER 2019
can find your nearest dealer by calling 1-800-448-7825 or
by using the dealer locator at https://www.icbus.com.
If you have already paid for repairs prior to this notice
that corrected the defect, you may be eligible for
reimbursement of certain repair expenses if they occurred
06/21/2018 thru 10/03/2019 Present your original repair
paperwork and proof of payment to any IC Bus dealer and
your eligibility will be reviewed. You may also submit a
claim using the enclosed Request for Reimbursement card.
If you are the lessor of this vehicle, please forward a
copy of this notice to the lessee within ten days to comply
with federal regulations.
If you do not own this vehicle, please fill out and return
mail the enclosed card so that you will not be contacted
again about this recall.
IF YOU NEED ASSISTANCE
If you believe that IC Bus has failed to remedy the defect
without charge or within a reasonable time, please follow
the procedure described in the Owner Assistance Guide
section in your Owner’s Manual or call toll free 1-800-448-
7825.
You may also submit a complaint to the Administrator,
National Highway Traffic Safety Administration, 1200 New
Jersey Ave, SE, Washington, DC 20590; or call the toll
free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-
424-9153); or go to https://www.safercar.gov.
IC Bus requests your prompt attention and patience
regarding the correction of this defect and apologizes for
any inconvenience this may cause you.
IC Bus, LLC
POSTED ON ISIS
SEP 16 2019
SUBJECT: SAFETY RECALL
MAILED
SEP 23 2019
19511
SEPTEMBER 2019
Shield Two-Point Lap Belt on certain 2011 IC Bus®
CE model commercial buses built 07 April 2010
thru 11 June 2010 with non-retractable passenger
two-point lap belts by Amsafe / Shield
DEFECT DESCRIPTION
Long term cycle fatigue (buckling and unbuckling the seat belt) may cause the
plastic fingers on the male portion of the buckle to crack and break off resulting
in an increase in force necessary to latch the seat belt buckle.
MODELS INVOLVED
This Safety Recall involves certain 2011 IC Bus® CE model commercial buses
built 07 April 2010 thru 11 June 2010 with non-retractable passenger two-point
lap belts by Amsafe / Shield.
ELIGIBILITY
This procedure applies ONLY to vehicles marked in the International® Service
Portal’M with Safety Recall 19511. Also complete any other open campaigns
listed on the Service Portal at this time.
PARTS INFORMATION
Part Number Part Description Quantity
8900283R91 Kit for Blue Seat Belts As
Required
8900284R91 Kit for Maroon Seat Belts As
Required
8900285R91 Kit for Brown Seat Belts As
Required
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
8900283R91 contains the following parts:
Part Description Quantity
Blue Seat Belt 1
BOLT, HEXAGON FLANGE W/LOCK WASHER 1
NUT HEXAGON FLANGE 3/8-16 GRADE 8 1
8900284R91 contains the following parts:
Part Description Quantity
Maroon Seat Belt 1
BOLT, HEXAGON FLANGE W/LOCK WASHER 1
NUT HEXAGON FLANGE 3/8-16 GRADE 8 1
8900285R91 contains the following parts:
Part Description Quantity
Brown Seat Belt 1
BOLT, HEXAGON FLANGE W/LOCK WASHER 1
NUT HEXAGON FLANGE 3/8-16 GRADE 8 1
SERVICE PROCEDURE
WARNING! To prevent personal injury, and / or death, or damage to
property, park vehicle on hard flat surface, turn the engine off, set the
parking brake and install wheel chocks to prevent the vehicle from moving
in either direction.
WARNING! To prevent personal injury, and / or death, or damage to
property, if the vehicle must be raised, do not work under the vehicle
supported only by jacks. Jacks can slip or fall over.
WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.
WARNING! To prevent personal injury, and / or death, or damage to
property, keep flames, sparks or other heat sources away from vehicle and
do not smoke while servicing the vehicle’s batteries. Batteries expel gases
which may cause an explosion resulting in personal injury and / or death,
or damage to property, avoid contact with any heat sources.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 2
1. Park vehicle on flat surface.
2. Shift transmission to Park or Neutral and set parking brake.
3. Turn vehicle ignition to Key OFF position.
4. Install wheel chocks.
2
0000457703
Figure 1. Seat Belt Latches
1. Top push release belt latch (rectangle button)
2. Side push release belt latch (square button)
5. Inspect all seat belts on vehicle:
a. If seat belt is equipped with a top push release belt latch (Figure 1,
Item 1 ), proceed to Step 6.
b. If seat belt is equipped with a side push release belt latch (Figure 1,
Item 2), proceed to Step 13.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 3
Figure 2. Seat Belt Bracket
1 . Seat belt bracket
6. Unlatch and raise bottom seat cushion to gain access to seat belt
brackets (Figure 2, Item 1 ).
VEHICLE RECALL 19511
0000457723
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 4
1 \
0000457743
Figure 3. Seat Belt Components
1. Bolt
2. Bracket
3. Nut
7. Remove and discard bolts (Figure 3, Item 1) and nuts (Figure 3, Item 3)
securing seat belt bracket (Figure 3, Item 2) to bus seat frame.
NOTE: When replacing the seat belt, make sure to replace with the same
color belt assembly.
8. Remove and discard seat belt from bus seat frame.
NOTE: The replacement seat belts have a shorter tether on the female
side of the seat belt than the original seat belt. The overall length of the
belt will not change.
9. Install new seat belt onto bus seat frame.
10. Install seat belts bolt and nuts, using a torque wrench, tighten to 30 – 38
lb-ft (41 – 52 N•m).
11 . Lower and latch bottom seat cushion after all top push release belts are
replaced for seat.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 5
12. Repeat Steps 6 through 11 until all necessary seat belts have been
replaced.
13. Remove wheel chocks.
END OF SERVICE PROCEDURE
LABOR INFORMATION
Operation Number Description Time
A40-19511-1 Inspect and Replace Seat Belts; First Seat
(3 Seat Belts) 0.4 hr
A40-19511-2 Inspect and Replace Seat Belts; Each
Additional 3 Seats or 9 Seat Belts
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with this
campaign must be marked with a CTS-1075
Campaign Identification Label.
Complete the label and attach on a clean surface
next to the vehicle identification number (VIN) plate.
ADMINISTRATIVE/ DEALER RESPONSIBILITIES
WARRANTY CLAIMS
0.2 hr
COMPLETED
Service Location Code’
Warranty claim expense is to be charged to Warranty. Claims are to be
submitted in the normal manner, making reference to Safety Recall 19511.
Section 7 of the Warranty Policy and Procedures Manual contains further
information related to the submission and processing of AFC / Recall claims.
As with all claim submissions, items acquired locally must be submitted in the
“Other Charges” tab. The cost of any bulk items (such as a bag of cable tie
straps, roll of wire, barrel of oil, or tube of silicone) should be prorated for the
cost of the individual pieces / amount used during each repair.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 6
GROUP
GROUP – Enter nu mber
NOUN – Leave b lank ~
~ I
–
C (CAUSE) – Ente r either 1, 2, 3. (See below)
1. Inspected (No repair required).
2. Inspected and repaired.
3. Defective p art from parts stock.
–
arranty Code) Enter 40.
I I
WARRANTY – (W
TYPE PART – En
PAD – Enter ‘()Q
ter P for type part causing failure. ~
. –
UNITED STATES AND POSSESSIONS
NOUN C WARR. TP PAD
I I I
I
CXXXl04 7910
The National Traffic and Motor Vehicle Safety Act, as amended, provides that
each vehicle that is subject to a vehicle recall campaign must be adequately
repaired within a reasonable time after the owner has tendered it for repair. A
failure to adequately repair within 60 days after a tender of a vehicle is prima
facie evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within 60 days, the owner may be entitled to replacement
with an identical or reasonable equivalent vehicle at no charge, or to a refund of
the purchase price less a reasonable allowance for depreciation.
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notifi cation Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 7
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
CANADA
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
EXPORT
Export Distributors should proceed immediately to make necessary correction to
units in inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your distributor location.
Export Distributors are to submit warranty claims in the usual manner making
reference to this recall number.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 8
Export Distributors are expected to provide full cooperation and follow-up with
respect to this important subject matter. If you have any questions or need
further assistance, please contact the Regional Service Manager at your regional
office.
NAVISTAR, INC.
VEHICLE RECALL 19511
© 2019 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 9
A 11,Wl.n;&R COMPANY
IC Bus, LLC
2701 Navistar Drive
Usie, IL 60532 USA
navlstar.com
IMPORTANT SAFETY RECALL 19511
INTERIM NOTICE
NHTSA RECALL NO. 19V-479
This notice applies to your vehicle Identified on the
enclosed card.
Dear IC Bus Customer,
This notice is sent to you in accordance with the
requirements of the National Traffic and Motor Vehicle
Safety Act.
IC Bus has decided that a defect which relates to motor
vehicle safety exists in certain 2011 CE model commercial
buses built 7 April 2010 thru 11 June 2010 with nonretractable
passenger two-point lap belts by
Amsafe/Shield.
REASON FOR THIS RECALL
Long term cycle fatigue (buckling and unbuckling the seat
belt) may cause the plastic fingers on the male portion of
the buckle to crack and break off resulting in an increase in
force necessary to latch the seat belt buckle.
RISK TO MOTOR VEHICLE SAFETY
All bus seats provide a safe environment regardless of belt
availability. However, in certain crashes, a risk of injury
could be impacted without the ability to properly latch the
belt.
DEFECT REMEDY
A remedy has been determined and parts have been
ordered. When parts become available, you will be notified
of additional actions you should take.
ACTIONS YOU SHOULD TAKE
To minimize the potential occurrence of this defect, ensure
belts are property stowed on the seat cushion when not in
use. Belts that slip through the seat base onto the floor are
more prone to damage.
MAILED
AU3 16 2019
Comp I iance Dept.
AUGUST2019
If you are the lessor of this vehicle, please forward a
copy of this notice to the lessee within ten days to comply
with federal regulations.
IF YOU NEED ASSISTANCE
You can find your nearest dealer by calling 1-800-448-7825
or by using the dealer locator at https://www.icbus.com.
You may also submit a complaint to the Administrator,
National Highway Traffic Safety Administration, 1200 New
Jersey Ave, SE, Washington, DC 20590; or call the toll
free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-
424-9153); or go to https://www.safercar.gov.
IC Bus requests your prompt attention and patience
regarding the correction of this defect and apologizes for
any inconvenience this may cause you.
IC Bus, LLC
1 Affected Product
Vehicle
| IC BUS | CE | 2011 |
10 Associated Documents
Recall Quarterly Report #2, 2019-4
RCLQRT-19V479-6069.PDF 211.228KB
Recall Acknowledgement
RCAK-19V479-4438.pdf 245.029KB
Miscellaneous Document- Supplemental Chronology
RMISC-19V479-2445.pdf 36.821KB
Defect Notice 573 Report
RCLRPT-19V479-4367.PDF 212.729KB
Remedy Instructions and TSB
RCRIT-19V479-7636.pdf 2385.269KB
Recall Quarterly Report #3, 2020-1
RCLQRT-19V479-8416.PDF 211.306KB
Recall 573 Report- Amendment 1
RCLRPT-19V479-7774.PDF 214.4KB
Recall Quarterly Report #1, 2019-3
RCLQRT-19V479-6565.PDF 211.124KB
Interim Owner Notification Letter(Part 577)
RIONL-19V479-1326.pdf 31.694KB
ISSUED Owner Notification Letter(Part 577)
RCONL-19V479-5001.pdf 507.167KB
Latest Recalls Documents
1 Associated Investigation
Lap seat belts fail to latch
NHTSA ID: PE18015
Dated opened: December 17, 2018
The Office of Defects Investigation (ODI) received a complaint from a school bus fleet in the state of New Jersey indicating seat belt failures in their model year 2015 school buses, built by Navistar, and equipped with Am Safe lap belts. The complaint states that the lap belt metal insert plastic cover breaks and prevents the insert from latching with the buckle. This fleet has replaced over 50 percent of the lap belts in their 8 buses. ODI reached out to Florida state school bus fleets to see if they had experienced the same problem since Florida is one of 6 states in the country requiring lap belts in their school buses. The state of Florida Director of Public School Bus Transportation contacted 20 municipalities and found maintenance records from 16 of the 20 fleets confirming seat belt buckle inserts broken in a similar fashion as those from New Jersey.
The following VOQ number is associated with the issues discussed in this opening resume: 11127877
A Preliminary Evaluation has been opened to evaluate the alleged defect conditions in the subject vehicles.
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