SB 481 – Front Brake Hose Failure/FMVSS 121 – 2014-2019 MCI J4500 & 2018-2019 J3500 Motor Coaches

April 27, 2020 NHTSA CAMPAIGN NUMBER: 20V233000

Front Brake Hose Failure/FMVSS 121

A leaking brake hose could cause a delay in the actuation time of the front brake, which would increase vehicle’s stopping distance and increase the risk of a crash.

 

NHTSA Campaign Number: 20V233

Manufacturer Motor Coach Industries

Components SERVICE BRAKES, AIR

Potential Number of Units Affected 2,272

 

Summary

Motor Coach Industries (MCI) is recalling certain model year 2014-2019 J4500 and 2018-2019 J3500 motor coaches. The brake hoses may crack or otherwise fail resulting in an air leak. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 121, “Air Brake Systems.”

 

Remedy

MCI will notify owners to inspect the brake hoses and replace any hoses that are leaking or otherwise damaged. MCI will reimburse owners for the cost of the inspection, and will provide replacement parts as necessary, free of charge. The recall began June 26, 2020. Owners may contact MCI customer service at 1-800-241-2947. MCI’s number for this recall is SB 481.

 

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.

 

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THIS SERVICE BULLETIN SUPERSEDES SERVICE BULLETIN 454.  MCI URGES YOU TO MAKE ARRANGEMENTS TO REPAIR YOUR AFFECTED VEHICLE(S) AS SOON AS POSSIBLE.

 

Subject: Front Brake Hose Rework
Field Change Program: Field Campaign	FCP Number: 481	Revision: A	Date:  06/24/2020
Coach Section:  04-Brakes & Air system	P/N: 04-20-1817		Type: Safety Recall

 

Ref. NHTSA Recall No.: 20V-233

Ref. Transport Canada Recall No.: 2020-179

 

Application:

Coach Model	Model Year	VIN
J4500	2014 – 2019	66554, 66748, 66796 – 66798, 66823, 66824, 66826, 66841, 66842, 66844, 66960, 67000 – 68117, 68119 – 68148, 68150 – 68605, 68607 – 68617, 68619 – 68677, 68679 – 68690, 68692 – 68716, 68718 – 68745, 68747 – 68771, 68773 – 68802, 68804 – 68876, 68878 – 68908, 68910 – 68934, 68936 – 68964, 68966 -69482, 69484 – 69502
J3500	2018 -2019	68877, 68909, 68935, 68965, 21000 – 21026
This field campaign does not necessarily apply to all the above-mentioned coaches.  The owners of the coaches affected by this field campaign will be advised by a letter indicating the Vehicle Identification Number (VIN) of each applicable coach.

 

Read this entire procedure before beginning work. 

Use Safe Shop Practices at All Times.

To avoid personal injury:

1. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and protective gloves are required for working with DEF Fluid.
2. Turn the main battery disconnect switch to the OFF position.
3. Ensure that both the front and the rear wheels are chocked.
4. Position the ENGINE RUN and ENGINE START switches on the engine compartment remote control box to the OFF
5. Allow enough time for components to cool down prior to working in the engine compartment.

 

1.0 Description

Customer complaint:

Motor Coach Industries (“MCI”) has become aware that on certain J4500 and J3500 model coaches, the front brake hoses may crack or otherwise fail due to their routing and clamping orientation, resulting in air leaking from the hose. As a result, brake performance could be affected. Reduced brake performance can cause extended stopping distances and increase the risk of a crash.

 

Cause:

With the current front brake hose routing and clamping orientation, the bend radius is too tight, causing compression set and metal reinforcement fatigue.

 

Corrective action:

MCI recommends owners of the affected coaches have the following procedure performed as soon as possible to replace the front brake hose and update the routing to eliminate the “S” bend in the brake hose, thereby reducing loading on the hose during suspension articulation.

 

2.0 Material requirements

Service kit 26-04-0069 contains the following parts:

ITEM	PART NO	QTY	U/M	DESCRIPTION
1	04-20-1890	2	EA	Hose assy- Brakes, Front
2	19-03-0519	8	EA	Nut-Hex, Lock, Flanged, 1/4-20
3	19-1-1303	12	EA	Screw-Cap, Hex, 1/4-20 UNC X 2.25 LG, 18-8 SST
4	19-2-37	4	EA	Washer-LK,HLCL,1/4 ID, SST
5	19-11-258	24	EA	Tyrap- 7.31” LG

 

3.0 Special tools

Thread sealer, MCI P/N: 23-06-0070 (Vendor: Loctite, VPN: 545) or equivalent.

 

4.0 Procedure

4.1 Coach preparation

Lift the coach at the specified locations as per MCI Maintenance manual. (Refer to the Appendix for the proper jacking point locations based on coach model.)

Remove and save the ten nuts on the hub cover of the front axle wheel. Save the hub cover

Remove and save the hub nuts and hub cover

Remove and save the ten flange nuts on the wheel. Remove and save the wheel.

Remove and save the flange nuts

 

WARNING

Tire and wheel assemblies weigh more than 200 lbs.

To prevent personal injury, use caution when loosening the wheel nuts, and when lifting the wheel off the hub.

 

4.2 Remove the existing brake hoses

Drain air off the coach following instructions in the maintenance manual. Cut and discard the cable ties securing the ABS sensor harness to the front brake hose assembly on the driver side. Disconnect the front brake hose assembly from the ABS front module and front brake chamber on the wheel.

Cut and discard the cable ties securing the ABS sensor harness to the brake hose

Remove the three clamps (A-post clamp, middle clamp, and frame bogie clamp), plates, and hardware securing the brake hose to the axle. Save the clamps and plates. Discard the hardware. Make sure not to remove the bracket securing the middle clamp.

Remove and save the clamps, discard the hardware.

Do not remove the bracket

Disconnect the front brake hose on the wheel end by holding the 90-degree fitting on the front brake chamber tight with a wrench.

Disconnect the brake hose.

Hold the 90-degree fitting with a wrench

 

CAUTION

Failure to hold the fitting with a wrench while loosening the brake hose may result in damaging the fitting.

Disconnect the front brake hose on the other end by holding the fitting on the ABS front module relay valve tight with a wrench. Discard the brake hose.

Remove and discard the brake hose.

Hold the fitting with a wrench

 

CAUTION

Failure to hold the fitting with a wrench while loosening the brake hose may result in damaging the fitting.

 

4.3 Installing the new brake hose

Identify the fitting on the side of the long spring guard on the new brake hose, MCI P/N: 04-20-1890.

Apply two drops of thread sealer, MCI P/N: 23-06-0070, to the previously identified end of the brake hose and install it to the 90-degree fitting on the front brake chamber. Hold the 90-degree fitting on the front brake chamber tight with a wrench while tightening the brake hose. Torque the brake hose fitting to 58 Ft-Lbs.

Install fitting on the long spring guard side to wheel hub

Hold the 90-degree fitting with a wrench

 

CAUTION

Failure to hold the fitting with a wrench while tightening the brake hose may result in damaging the fitting.

Make a mark on the hose at 20.82” from the end of the fitting and align it with the front face of the A-post clamp.

Make a mark 20.82” from the end of the fitting

Re-install the existing A-post clamp and plate using bolts, MCI P/N: 19-1-1303, and lock washers, MCI P/N: 19-2-37. Ensure the long spring section is completely between the fitting and the clamp and is not compressed on areas of the hose assembly with spring guard. Torque the bolt to 9 Ft-Lbs.

Secure the hose to the spacer plate using existing clamp, plate, bolts, 19-1-1303 and lock washers, 19-2-37

Ensure that the hose between the front brake chamber and A-post clamp is routed perpendicular to the 90° fitting on the front brake chamber.

Route the brake hose perpendicular to the 90° fitting on the front brake chamber

Make a mark on the hose at 8.25” from the back face of the A-post clamp and align it with the front face of the middle clamp.

Make a mark 8.25” from the back face of the A-post clamp

Re-install the existing middle clamp and plate using bolts, MCI P/N: 19-1-1303, and nuts, MCI P/N: 19-03-0519. Ensure the middle section of the spring is between the clamps and is not compressed on areas of the hose assembly with spring guard. Torque the nuts to 9 Ft-Lbs.

Secure the hose to the middle bracket using existing clamp, plate, bolts, 19-1-1303 and nuts, 19-03-0519

Make a mark on the hose at 12.5” from the back face of the middle clamp and align it with the front face of the frame bogie clamp.

Make a mark 12.5” from the back face of the middle clamp

Re-install the existing frame bogie clamp and plate using bolts, MCI P/N: 19-1-1303, and nuts, MCI P/N: 19-03-0519. Ensure the short section of the spring is between the clamps and is not compressed on areas of the hose assembly with spring guard. Torque the nuts to 9 Ft-Lbs.

Secure the hose to the welded bracket on the frame using existing clamp, plate, bolts, 19-1-1303 and nuts, 19-03-0519

Apply two drops of thread sealer, MCI P/N: 23-06-0070, to the fitting on the free end of the brake hose and install it to the ABS front module relay valve. Hold the fitting on the BAS front module relay valve with a wrench while tightening the hose. Torque the fitting to 58 Ft-Lbs.

Install the free end of the hose to ABS front module relay valve

Hold the fitting with a wrench

 

CAUTION

Failure to hold the fitting with a wrench while tightening the brake hose may result in damaging the fitting.

Secure the ABS sensor harness to the front brake hose using cable ties, MCI P/N: 19-11258. Use as many cables ties as required to secure the harness.

Secure the ABS sensor harness to the front brake hose using cable ties, 19-11-258

Repeat all the steps on the street side brake hose.

 

4.4 Re-Installing the tire

Install the wheel using existing flange nuts and hand tighten the nuts.

Install the wheel using flange nuts

Torque the nuts to 450-500 Ft-Lb in the sequence shown below.

Sequence of the nuts to torque

Install the hub cover using the existing nut covers. Turn the nut covers approximately five full turns until the nut cover clamps the hub cover tightly against the wheel.

Install the hub cover using nut covers

             

5.0 Field Change Program Conditions:

The parts required for this change will be supplied without charge.

A labor allowance of 1 hour will be granted for the rework.

This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached “MCI Field Change Program Verification Form” and a “Warranty Claim Form” as detailed in your Owner Warranty manual to MCI’s Warranty department. A “MCI Field Change Program Verification Form” needs to be submitted for each VIN affected. Photocopy the attached “MCI Field Change Program Verification Form” as required for the number of affected coaches in your fleet.

Motor Coach apologizes for any inconvenience resulting from this campaign but urges you to implement this change as soon as possible.

Sincerely,

Motor Coach Industries

 

6.0 Appendix

J4500 Jacking points:

Lift the coach at the six jacking points

 

J3500 Jacking points:

Lift the coach at the four jacking points

 

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THIS LETTER SUPERSEDES AN EARLIER NOTICE SENT WITH RESPECT TO RECALL 17V-360 (NHTSA) / 2017-291 (TRANSPORT CANADA).  MCI URGES YOU TO MAKE ARRANGEMENTS TO REPAIR YOUR AFFECTED VEHICLE(S) AS SOON AS POSSIBLE.

 

June 26, 2020

 

IMPORTANT SAFETY RECALL

This notice applies to your vehicle(s) [«UNIT»]

 

«CUST_NAME»
ATTENTION:  TECH SERVICE DEPT/MAINT
«ADDRESS_1»
«CITY», «STATE» «ZIP»
USA

 

SUBJECT:	SAFETY RECALL:  FRONT BRAKE HOSES
Ref.:	NHTSA # 20V-233 Transport Canada # 2020-179 MCI Service Bulletin 481

 

Attention Owner:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act and the Canadian Motor Vehicle Safety Act.

Motor Coach Industries, Inc. (“MCI”) has decided that a defect which relates to motor vehicle safety exists on certain MCI model year 2014 – 2019 J4500 and model year 2018 – 2019 J3500 motor coaches.  Due to their routing and clamping orientation, the brake hoses on affected vehicles may crack or otherwise fail, resulting in air leaking from the hose.  If the brake hose leaks, it could cause a delay in the actuation time of the front brake, which could increase vehicle stopping distance and potentially result in a crash causing injury.   Please see the enclosed MCI Service Bulletin 481 for further information.

MCI is conducting a recall of the affected vehicles to repair the defect condition.  Please see the enclosed MCI Service Bulletin 481 for further information.  MCI is providing a service kit with replacement parts at no cost to you, and labor reimbursement.  MCI estimates that it will take approximately one hour to make the necessary repairs.

 

MCI records indicate that you are the owner or operator of the following vehicle(s) included in this recall:

«Unit_Numbers»

MCI urges you to have the recall work performed on your vehicle(s) as quickly as possible.

 

You may contact the MCI Customer Service Line at 1-800-241-2947 if you have any questions about this recall campaign or wish to make arrangements to have your vehicle(s) repaired at an authorized MCI service center.  Submittal of MCI Warranty Claim Forms may be completed on MCI’s website at https://fleetsupportiw.mcicoach.com/iwarranty/signon (click on Customer Care System), or a photocopy of the Warranty Claim Form found in the Warranty Manual can be mailed / faxed to the MCI Warranty Department.  Please refer to Service Bulletin 481, and your OWNER LIMITED WARRANTY MANUAL, for more detailed information.

 

After contacting MCI Customer Service, if you are still unable to have the safety defect remedied without charge and within a reasonable time, you may submit a complaint:

 

For US customers:

You may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call 888 327-4236 (TTY: 800-424-9153), or go to https://www.safercar.gov if remedy difficulties exist.

 

For Canadian customers:

Please contact our customer service at 1-800-241-2947, or for additional information about the recall, you can contact Transport Canada at 1-800-333-0510.

If you are the lessor of the vehicle(s) identified above, Federal law requires that you forward this notice by first class mail to the most recent lessee(s) known to you, within ten days of your receipt of this notice.

If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s).

If you had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement.  Please contact the MCI Customer Service Line at 1-800-241-2947 for further information in that regard.

We regret the inconvenience this may cause you, but urge you to implement the recall procedures with respect to your vehicle(s) as soon as possible for your added safety and satisfaction.

 

Sincerely,
Motor Coach Industries
Warranty Department

 

Enclosure: MCI Service Bulletin 481

 

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8 Affected Products

Vehicles

MAKE	MODEL	YEAR
MCI	J3500	2018-2019
MCI	J4500	2014-2019

 

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6 Associated Documents

Remedy Instructions and TSB

RCRIT-20V233-7074.pdf 1959.576KB

 

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Recall Acknowledgement

RCAK-20V233-3288.pdf 292.622KB

 

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Defect Notice 573 Report

RCLRPT-20V233-7670.PDF 214.95KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V233-6492.pdf 197.742KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V233-2232.PDF 211.233KB

 

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V233-1554.PDF 211.326KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V233&docType=RCL

 

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