CR4943 – Loss of Drive from Fractured Pressure Switch – 2016 Nova LFS & LFS Artic Buses

SEOCONTENT-START

REFERENCE: Nova Bus Manuals
SECTION: 10: Allison electric drive Ep -40/50
sytem
RS NO: N/A
EFFECTIVE IN PROD.: N/A
TC RECALL NO: N/A
NHTSA RECALL NO: 20V457
MATERIAL
QTY PART NO REV. DESCRIPTION REPLACES PART N°
LEVEL 1
– – – – –
LEVEL 2
– – – – –
Materials will be available via the Allison Transmission distribution network.
LEVEL DESCRIPTION
DIRECT CHARGES
TIME
LABOUR MATERIAL
1 Contact your nearest Allision transmission certified service center. Allison Allison 1,2 to
4 h
2 – – – –
SUBJECT: Allison electric drive Ep -40/50
JUSTIFICATION:
Allison Transmission Inc. informed Nova Bus that some pressure switches used in the
switch assembly may fracture. This condition may result in a loss of propulsion with no
possibility of regaining it.
REVISION HISTORY
REV. DATE CHANGE DESCRIPTION WRITTEN BY
NR 2020AU14 Initial release Luc Carignan
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED * RETAINED * Dispose of the unused parts and the defective parts in
Yes – accordance with local environmental standards in effect.
APPROVED BY:
APPLICATION DEADLINE: NA
CLAIM REFERENCE NUMBER: SR-4943
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CLIENT ORDER
ROAD NUMBER VIN (2NVY/4RKY…)
QTY
FROM TO FROM TO
SEPTA – Pennsylvania L861 7300 7484 S92L5G9775188 S92L8G9775220 32
Duke University – North Carolina L938 – – L82L8G9775399 L82L0G9775400 2
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PROCEDURE
1.1. Contact your nearest Allison Transmission Inc. certified service center to have the requirement of this recall
campaign done to your vehicles.
NOTE
Allison Transmission Inc. has provided the manufacturer defect notice and work instruction included in this
document. Nova Bus cannot be held responsible under any circumstances for the content of this procedure.
WARNING
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
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Allison Transmission Inc. | One Allison Way | Indianapolis, IN 46222-3271
*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 20E049
This notice applies to your [ENTER NAME] set:
Drive Unit Serial Number Bus Manufacturer Bus Vehicle Identification Number (VIN)
XXXXXXXXX XXXXXXXX XXXXXXXXXXXXXX
August XX, 2020
Customer
XXXX CENTRAL AVE
ALBANY NY 12205-2457
Dear Allison Transmission Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle
Safety Act.
Allison Transmission Inc. (ATI) has decided that a defect which relates to motor vehicle safety exists in
certain H 40/50 EP Drive UnitsTM manufactured between January 4, 2016 and December 22, 2016. Our
records indicate that your Allison drive unit(s) listed above is (are) affected. This recall expands the scope
of a previously announced campaign, NHTSA Recall No. 18E085, to address the same concern. The
drive units listed above are in addition to units shipped to you that may have been covered by Recall No.
18E085.
WHY IS A RECALL BEING CONDUCTED?
Due to an out-of-specification material condition at the pressure switch supplier, the plastic molding used
in the switch assembly may fracture. This condition may result in a failure of the pressure switch in either
an open or closed state, triggering a diagnostic trouble code. In some circumstances, switch failures in
the closed position can potentially disable propulsion at any time during a drive cycle without the ability to
regain propulsion, presenting an increased risk of a vehicle accident and/or risk related to offloading
passengers in the roadway.
WHAT ARE WE DOING ABOUT THE PROBLEM?
ATI’s authorized service network will be utilized to replace the C1 and C2 pressure switches used in each
affected drive unit at no charge (parts and labor). ATI expects the repair time to range from 1.2 to 4.0
hours, excluding vehicle and shop logistics. [SHOULD WE REFER TO THE TSB?]
WHAT SHOULD YOU DO?
Contact the nearest authorized Allison service outlet to arrange to have this campaign performed on your
drive unit. The service outlet will work with you to schedule the best date to complete this repair.
Federal law requires vehicle lessors receiving this recall notice to forward a copy of this notice to the
lessee within ten (10) days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle or
equipment covered by this recall notice under a sale or lease until the defect has been remedied.
QUESTIONS OR CONCERNS?
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If you have questions or concerns about this recall, please contact your local Allison Authorized facility.
You may also contact Allison’s TAC at (800) 252-5ATD (5283).
If you have a complaint relative to this recall, you may report it to the following:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, SE
Washington, DC 20590
You may also call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
https://www.safercar.gov.
If you are no longer the owner of the vehicle(s) listed above, please forward this notice to the new owner
or provide the new owner’s contact information to Allison’s TAC at the number above so that we can
notify the new owner of this recall.
Allison is taking this action in the interest of safety and satisfaction with our products. We apologize for
any inconvenience and thank you for your attention to this matter.
Sincerely,
Campaign Administrator
Allison Transmission Inc.
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Revisions to this document are noted
by a stripe in the left-hand margin
2018FA07, Rev. C
July 17, 2020
Page 1 of 9
SUBJECT: H 40/50 EPTM Drive Unit C1/C2 Pressure Switch
MODELS AFFECTED: H 40/50 EPTM Drive Unit
Introduction:
Allison Transmission, Inc. (ATI) has identified an issue with the pressure switch (P/N 29506484) used in a specific
population of H 40/50 EPTM Drive Units. The Drive Units, within the serial number range specified below, were built
with pressure switches that can fail in an either open or closed state. The failure can cause diagnostic trouble
codes (DTCs) to set which may disable the corresponding clutch, locking the Drive Unit into the unaffected
range with reduced performance, or disable propulsion. Additionally, a subset population of Drive Units within the
same serial number range may have debris in valve bodies or internal passages that could prevent proper valve
operation. The purpose of this Field Action is to proactively replace the two (2) pressure switches used in each
of the affected Drive Units, and inspect and remove debris in the subset population according to the procedure
included in this Field Action.
Prior to working on vehicles, please read SIL 21-TR-18, Defective Normally Open Pressure Switch P/N 29506484,
for parts information. All replacement pressure switches installed in the affected Drive Unit serial number ranges
must be stamped with a date code of 1918 or later.
Serial Number Range:
The serial number range included in this Field Action is 7110008473 through 7110009446. All serial numbers in this
range will require the two (2) pressure switches to be replaced.
The serial numbers of the subset population requiring the additional debris inspection and removal are 7110009294
through 7110009445.
Repair Process Overview:
All buses equipped with a Drive Unit serial number 7110008473 through 7110009446 will need to have the oil
drained into a clean container for reuse. The oil pan will be removed and the two (2) pressure switches replaced.
Refer to Allison Electric Drives Service Manual SM3602 Section 5-12 for pan removal and Section 6-15, C1/C2
Relay Valve Body, for switch replacement.
For buses equipped with a Drive Unit serial number 7110009293 through 7110009445, valve bodies will need
removed, inspected for debris, and compressed air blown through the C1 and C2 pressure taps in the rear cover to
remove any potential debris, followed by pressure switch replacement. Instructions for Drive Unit serial numbers
7110009293 through 7110009445 are provided at the end of this document. Refer to Allison Electric Drives Service
Manual SM3602 Sections 5-13 through 5-17 for disassembly and Sections 6-13 through 6-15 for installation.
ML / FA8182EN 5217307
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 2 of 9
Table 1. ATI Required Service Parts
Part Description Part Number Quantity Per Bus
Pressure Switch, N/O 29506484 2
O-Ring, Switch 29501439 2
Gasket, Oil Pan 29538847 1
O-Ring, Drain Plug 23019664 1
O-Ring, Filter 23018950 1
Claim Submittal Information:
For all proactive repairs, refer to Table 2 and Table 3 below for claim submittal information.
For all claims made against repairs that are not proactive; where a pressure switch is already failed before it could
be pro-actively replaced, refer to Table 4 and Table 5 below for claim submittal information.
NOTE: Drive unit serials 7110008473 through and including 7110008854 may already have a claim
for non-proactive pressure switch replacement. Please ensure that any serial in this range with a
non-proactive claim has had both C1 and C2 pressure switches replaced with new pressure switches.
Table 2. Proactive Repair Claim Information
Claim Type 04
Special Activity Indicator 2018FA07
Primary Failed Part 29506484
Complaint Code AT02
Failure Code CC03
Table 3. Proactive Repair Labor Codes
Labor Code Labor Hours Labor Operation
00094100 1.2 R&R Oil Pan and Fluid
00096100 0.2 Switch Replacement
00094700 2.8 Debris Inspection
00096400 0.5 Final Test Drive
Refer to Table 4 and Table 5 below for non-proacitve repair claims.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 3 of 9
Table 4. Non-Proactive Repair Claim Information
Claim Type 01
Special Activity Indicator 2018FA07
Primary Failed Part 29506484
Complaint Code EL02
Failure Code AC00
Table 5. Non-Proactive Repair Labor Codes
Labor Code Labor Hours Labor Operation
00094100 1.2 R&R Oil Pan and Fluid
00096100 0.2 Switch Replacement
00094700 2.8 Debris Inspection
00096400 0.5 Final Test Drive
00096901 0.5 Troubleshooting and Diagnostics
Any additional parts, labor, net items, or travel costs deemed necessary to complete this Field Action must be
described in detail in the claim narrative. Unexplained costs will be deducted from the claim.
Authorized Allison service outlets must follow the published Allison Transmission current labor time guide for
work performed when adding any additional charges.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 4 of 9
Procedure for Inspection and Removal of Debris:
1. With the Drive Unit installed, drain the fluid into a clean container for reuse, and drop the oil pan from the
Drive Unit.
Figure 1.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 5 of 9
2. Remove the suction filter and unplug all connectors on the internal harness.
Figure 2.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 6 of 9
3. Remove the oil level sensor, C1/C2 valve body, shift relay valve body, control main valve body, and separator
plate.
Figure 3.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 7 of 9
4. Remove the C1 and C2 plugs (shown below) on the backside of the rear cover.
Figure 4.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 8 of 9
5. Starting with the C2 pressure circuit, plug the 4mm orifice on the stator housing, as shown below. Pressurize
the C2 pressure tap on the rear cover with air to blow out any debris. Check the previously plugged 4mm
passage for loose debris and remove if any is found.
Figure 5.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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2018FA07, Rev. C
July 17, 2020
Page 9 of 9
6. To inspect the C1 pressure circuit, plug the 4mm orifice on the opposite side the stator housing, as shown
below. Pressurize the C1 pressure tap on the rear cover with air to blow out any debris. Check the previously
plugged 4mm passage for loose debris and remove if any is found.
Figure 6.
7. Inspect the removed valve bodies and the separator plate for any machine chips or debris. Verify proper
valve movement. If any debris is found, additional valve body teardown should be performed. Replace
any components that may have damage.
8. Reassemble the valve bodies and install two (2) new pressure switches (P/N 29506484) and O-rings (P/N
29501439). New switches must be stamped with date code 1918 or later on the metal retainer ring.
Figure 7. Date Code Format
9. Reassemble remaining parts, refill the Drive Unit, and test drive to verify proper operation.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
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***************************************************************************************

NCVaBUS
Nova Bus, a division Prevost Car (US) Inc.
IMPORTANT SAFETY RECALL
THIS NOTICE APPLIES TO YOUR VEHICLE – SEE VIN IN ANNEX A
– Notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle
~ tyAct.
Nova Bus has decided that a defect which relates to motor vehicle safety exists in certain Nova Bus LFS
and LFS Artie Model Year 2016 manufactured from March 14th 2016 to July 18th 2016 and equipped with an
H 40/ 50 EP Drive Units.
Nova Bus have voluntary filed the vehicle recall 20V457 and will issue a recall campaign service document
CR4943 to address this situation.
Following the equipment recall 20E049 received from Allison Transmission Inc, certain affected vehicles
may have a pressure switch assembly that may fracture. In addit ion, on some units, machining debris may
contaminate the valve body internal passages affecting valve operation. Either condit ion may result in a
failure of the pressure switch in either an open or a close state, triggering a diagnostic trouble code. In
some circumstances, switch failures in the closed position can potentially disable propulsion at any time
during a drive cycle without the ability to regain propulsion, presenting an increased risk of a vehicle
accident and/or risk related to offloading passengers in the roadway.
Nova Bus will release a service document explaining the remedy program. This document will be available
to you on our web site at https://www.novabus.com/on-line-services.html. The necessary replacement parts
are available via the Prevost Parts distribution network. Nova Bus will assume the parts and labour costs
according to the warranty claim policies in effect. The vehicle can be remedied starting from August 14th
2020 (according to Allison Transmission Inc. kit availability). The repairs should take approximately 1.2 to
4 hours to complete.
Any lessor who receives a notification of a determination of a safety-related defect or noncompliance
pertaining to any leased motor vehicle shall send a copy of such notice to the lessee. This requirement
applies to both initial and follow-up notifications.
260 Banker Rd, Plattsburgh, NY, USA 12901 I Tel.: 1 800 350-6682 i Fax: 450 974-3001 I novabus.com
260 Banker Rd, Plattsburgh, NY, USA 12901 | Tel.: 1 800 350-6682 | Fax: 450 974-3001 | novabus.com
After contacting your customer support manager, if you are still not able to have the safety defect remedied
without charge and within reasonable time, you may submit a complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590; or call the
toll-free Vehicle Safety Hotline 1-888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.
You may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of a
problem associated with this defect. Submit copies of all documentation supporting your claim according
to the rules specified in the “General Plan for Reimbursement of Pre-notification Remedies” provided in this
mailing under the heading “Annex B”.
If you have any questions regarding the requirements of this campaign, please contact your customer
support manager.
Sincerely,
Guy French
Vice-President General Manager Services
NDVaBUS

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