SC0433 – Park Brake Control Valve – 2008-2022 Mack TerraPro

December 9, 2021 NHTSA CAMPAIGN NUMBER: 21V953000

Parking Brake May Release Unexpectedly

The unexpected release of the parking brake may allow the vehicle to rollaway, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V953

Manufacturer Mack TruckseBay logo, Inc.

Components PARKING BRAKE

Potential Number of Units Affected 20,668

 

Summary

Mack TruckseBay logo, Inc. (MackeBay logo) is recalling certain 2008-2019 TerraPro (MRU) and 2019-2022 TerraPro (TE) vehicles. A brake control valve air leak into the attached exhaust hose can create excessive back pressure, causing the parking brake to release unexpectedly.

 

Remedy

Dealers will remove the exhaust tube and fitting from the valve, free of charge. Owner notification letters were mailed February 8, 2022. Owners may contact MackeBay logo customer service at 1-800-866-1177. MackeBay logo’s number for this recall is SC0433.

 

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.nhtsa.gov.

 


Description

A worn PP1 valve (park brake control valve) exhibiting an internal leak may cause air to pass through and out the exhaust port when the park brake is applied. Under certain conditions, the internal leak in combination with the installation of an exhaust hose may result in back pressure sufficient to allow the park brakes to release.

 

This results in a potential of a vehicle rollaway with the park brake control valve in the on/applied position, which may result in a vehicle crash, property damage and/or personal injury.

 

The exhaust tube and fitting will be removed from the valve.  With the exhaust tube removed, a notable rush of air may now be heard from behind the dash during park brake apply. This is normal.

 

Model and Model Years Affected

  • Certain 2008 โ€“ 2022 MackeBay logo TerraPro (MRU, TE) model vehicles manufactured from January 4, 2007 through December 6, 2021.

 

Vehicle Quantities

  • 23,473 (20,668 US, 2,624 Canada, 181 Export)

 


DateNumberRelease
12.2021SC043301

 

Park Brake Control Valve

MRU, TE

 

RECALL INFORMATION

(December, 2021)

MackeBay logo has determined that certain model year 2008 – 2022 trucks may experience a worn PP1 valve (park brake control valve) exhibiting an internal leak that may cause air to pass through and out the exhaust port when the park brake is applied. Under certain conditions, the internal leak in combination with the installation of an exhaust hose may result in back pressure sufficient to allow the park brakes to release.

To help address this safety concern, MackeBay logo is releasing this recall to remove the park brake control valve vent line and fitting, and notifying owners of BendixeBay logoโ€™s guiding document for inspection and replacement of the park brake control valve.

 

VEHICLES AFFECTED

Certain 2008 โ€“ 2022 MackeBay logo TerraPro (MRU, TE) model vehicles manufactured from January 4, 2007 through December 6, 2021.

 

VEHICLE QUANTITY

There are 23,473 vehicles affected by this recall (20,668 U.S., 2,624 Canada, 181 Export).

 

Repair Instructions

1. Secure vehicle for service.

2. Ensure the ignition switch is in the off position and disconnect the negative battery cable.

3. Remove the instrument cluster module and lay forward.

 

4. Remove HVAC (heating ventilation air conditioning) panel.

 

5. Remove outer steering column cover.

 

6. Remove inner steering column cover.

 

7. Remove Lower right kick panel.

 

8. Remove the roll pin and the park brake button. Also remove the brake handle knob.

 

9. Remove the secondary gauge panel.

 

10. With all the panels removed, locate the park brake control valve (PP1) vent line. The vent line is directly opposite the yellow push pull button.

 

11. Cut the park brake control valve (PP1) vent line and remove the vent line fitting.

 

12. Reassemble vehicle in reverse operation of disassembly. Torque for the interior panel fasteners is 10 Nm ยฑ 1.5 (7 lbf-ft ยฑ 1).

 

NOTE: The left behind vent line can be left in place with no consequence. With the vent line and fitting removed the venting air will be heard by the operator every time the park brake valve is cycled. The sound of venting air will need to be explained to the operator/owner as normal operation.

 

NOTE: The park brake valve (aka PP1) does have an inspection process mandated by the manufacture. The guiding document for inspection and replacement is the BendixeBay logo bulletin number TCH-003-056. This document can be found by visiting BendixeBay logo.com โ€“ Document Library โ€“ search โ€œTCH-003-056โ€. This process should be read and followed for the life of the vehicle.

See page 8 for attached document.

 

13. Release the vehicle to service.

 

REIMBURSEMENT

This repair is covered by an authorized safety recall. Reimbursement is obtained through the normal claim handling process.
UCHP Reimbursement
Claim Type (used only when uploading from the Dealer Business System)40
Recall Status
Vehicle repaired per instructions1-Modified per instructions
Labor Codes
Primary Labor Code:

 1720-16-09-01 Campaign, General  (0.1 x 6)

0.6
Causal Part 25117989
Authorization Number SC0433

 

Note: Dealers are to perform Safety Recall on all subject vehicles at no charge to the vehicle owner regardless of mileage, age of vehicle or ownership (original purchaser or subsequent purchasers). Whenever vehicles are subject to a Safety Recall are brought to your dealership for service, or taken into your dealership vehicle inventory, it is strongly recommended that every effort be made to perform the recall correction before the vehicle is sold or released to the owner.

 


Technical Bulletin

Bulletin No: TCH-003-056 | Effective Date:  11-20-2019 | Cancels: N/A

Subject: BENDIXeBay logoยฎ PP-1ยฎ & PP-8โ„ข PARK CONTROL VALVE WEAR AND REPLACEMENT NOTICE

This bulletin applies to all BendixeBay logoยฎ PP-1ยฎ and PP-8โ„ข valves in applications where the exhaust port is plumbed external to the cab.  It is mostly applicable to vehicles used in high-park-brake-cycle count applications, like refuse vehicles or city buses.

When a heavily-worn PP-1 or PP-8 control valve is combined with restrictive exhaust plumbing, the vehicle park brake force may be reduced.  Valve wear may be the result of high-park-brake-cycle count and/or sideloading. Sideloading can be caused by pushing or pulling the valve button at an angle and not in line with the valve or from hanging objects from the button. See the table below for troubleshooting recommendations.

BendixeBay logoยฎ Valve ModelExhaust PortRecommendation
Port SizeFittingTube
PP-1ยฎ & PP-8โ„ข1/8โ€ NPTNoNoMaintain valve per Service Data sheet SD-03-3611.
YesYes or NoFollow the procedure below.
1/4โ€ NPTNoNoMaintain valve per Service Data sheet SD-03-3611.
YesLess than 1/2โ€ ODFollow the procedure below.

 

DIAGNOSING A LEAKING PP-1 AND PP-8 PARK CONTROL VALVE

When performing any inspection or service, follow the steps below and refer to the guidelines outlined in the PP-1 and PP-8 Service Data sheet SD-03-3611, or instruction sheet as applicable.

1. Run the vehicle until the air system reaches full reservoir pressure (120-135 psi). Turn off the vehicle.

2. Move the control valve button & plunger from side to side and up and down. Do not push the button in. If there is any play, or if audible leakage is detected, the valve must be replaced.

3. Identify the dash valve exhaust hose location (generally near the grill). With the button pulled out (exhaust position), there should be no audible leakage.  Rotate the button and plunger in a clockwise direction โ€“ stopping every 90ยบ to check for leakage. A second inspector near the end of the exhaust hose would be helpful for this procedure. There should be no audible leakage in the cab or from the exhaust hose at any point of rotation. Using a soap solution, check for leaks. The allowable leakage should not exceed a 1โ€ bubble in 5 seconds at any location on the valve.

4. Push the button in (applied position) and check for leaks. The leakage should not exceed a 1โ€ bubble in 3 seconds at any location on the valve.

5. Reduce the supply pressure. At a pressure from 60 to 20 psi, depending on the spring installed, the button should pop out automatically, exhausting the delivery volume. (This does not apply to the PP-8 or some PP-1 valves without an automatic exhaust feature).

For additional assistance contact the BendixeBay logo Tech Team at 1-800-AIR-BRAKE, option 2 (1-800-247-2725, option 2) or techteam@bendixeBay logo.com.

 


Chronology :

May 30, 2019 MackeBay logo notified of incident involving a MackeBay logo MRU.

Jun 6, 2019 Joint inspection of vehicle performed; components removed for further examination.

Jun 14, 2019 MackeBay logo informs NHTSA of incident/ investigation.

Jun 18, 2019 MackeBay logo provides notes/ minutes to investigation team.

Jul 19, 2019 MackeBay logo receives results on valves removed from fleet ownerโ€™s vehicles. Valves deemed as worn and
leaking requiring replacement.

Feb 2020 Incident reported to MackeBay logo. Team deployed to investigate matter.
MackeBay logo informs NHTSA of the report/ investigation.

Mar 2020 Results of investigation received. No issues found with brake system. Information shared with
owner.

Apr 1, 2020 NHTSA opens PE20-003 to further investigate matter. Apr 20, 2020 MackeBay logo receives PE
questionnaire from NHTSA.

Jun 1, 2020 MackeBay logo responds to NHTSAโ€™s inquiry.

Jul 23, 2020 Investigation raised for review at MackeBay logoโ€™s Product Safety Committee (PSC). PSC supports conclusion of Product Safety Working Group (PSWG) that the reports are not associated with a safety defect.

Aug 10, 2020 Informs that MackeBay logoโ€™s position is that the reported concern is not a safety defect.

Aug 16, 2021 MackeBay logo Sales team receives a report of an incident involving a 12-year-old rear load packer.

Aug 20, 2021 Additional information provided to MackeBay logo regarding the incident.

Aug 27, 2021 MackeBay logo PSWG informed of incident. MackeBay logo informs NHTSA of the report.

Sept 8, 2021 MackeBay logo facilitates a mtg with NHTA, Owner, and supplier.

Sept 15, 2021 Additional information shared with all parties; including information that the valve installed in the vehicle was an aftermarket replacement (not an OE replacement and different brand/ size).

Sept 30, 2021 PSC meets and re-visits case. Additional information required.

Dec 2, 2021 PSWG presents findings to PSC. PSC determines a safety defect.

Dec 9, 2021 MackeBay logo submits defect report to NHTSA.

There are 2 consumer complaints, 3 field reports, and 5 reports involving a crash and/or injury.

 


16 Affected Products

Vehicles

MAKEMODELYEAR
MACKeBay logoTERRAPRO (MRU)2008-2019
MACKeBay logoTERRAPRO (TE)2019-2022

 


10 Associated Documents

Remedy Instructions and TSB

RCRIT-21V953-1477.pdf 1341.35KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V953-4293.pdf 121.117KB

 


Defect Notice 573 Report

RCLRPT-21V953-1969.PDF 214.588KB

 


Recall Acknowledgement

RCAK-21V953-7020.pdf 737.438KB

 


Recall 573 Report – December 16, 2021

RCLRPT-21V953-1409.PDF 214.588KB

 


Recall 573 Report – December 16, 2021

RCLRPT-21V953-7491.PDF 214.588KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V953-5447.pdf 140.573KB

 


Recall Quarterly Report #1, 2022-1

RCLQRT-21V953-9892.PDF 211.133KB

 


Recall Quarterly Report #2, 2022-2

RCLQRT-21V953-0241.PDF 211.239KB

 


Recall Quarterly Report #3, 2022-3

RCLQRT-21V953-7632.PDF 211.318KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V953&docType=RCL

 


1 Associated Investigation

Vehicle Roll Away
NHTSA ID: PE20003
Dated opened: April 1, 2020

The Office of Defects Investigation (ODI) received a tip from a large fleet operator of refuse trucks about a potential defect condition that may result in a vehicle roll away. The subject vehicles are single-unit trucks equipped with certain BendixeBay logo PP-1 push-pull pneumatic park brake control valves. These subject components are mounted to the dashboard and allow the driver to apply and release the parking brakes. They have a 1/8โ€ NPT threaded fitting in the exhaust port and an exhaust pipe to vent exhaust air outside the truck cab.

The subject components may experience an accelerated wear out condition in certain severe-duty applications with high-frequency use of the parking brakes. When the knob is pulled out to apply the parking brakes, supply side air may continuously leak past the worn valve and escape through the exhaust port. This wear out condition may not be readily detected by the driver because the sound is muffled by the exhaust pipe configuration. An exhaust flow restriction, such as an insufficient diameter exhaust port, threaded fitting or exhaust pipe, may allow back-pressure to develop and pressurize the delivery port. This may inadvertently send a signal to the park control port of the SR-7 spring brake modulating control valve to release the parking brakes, possibly resulting in a vehicle roll away.

The reporting fleet operator is aware of at least 4 roll away incidents related to the alleged defect on subject vehicles in the United States. In one case, surveillance video recorded the driver applying the parking brakes moments before the vehicle rolled away. In some cases, the root cause was determined by post-incident examination of subject components by the component supplier and/or by a third-party forensic engineering company hired by the fleet operator. In one incident, a subject vehicle rolled more than 100 meters away and crashed into a parked car and a residential structure, causing in excess of $150,000 in property damage. In another incident, a subject vehicle rolled away and crashed into several other refuse trucks parked at the depot. The reported injury incident occurred when a driver dumped a load of refuse at a landfill, pulled into the clean out area, set the parking brakes, locked out the main battery disconnect and proceeded into the rear body to perform normal clean out duties. While inside the rear body, the driver reportedly heard the sound of rushing air, the parking brakes reportedly released and the truck began to roll away. In a panic, the driver jumped out of the moving vehicle and broke his ankle, which later required surgery. The truck came to rest approximately 50 meters away against a dirt berm.

A Preliminary Evaluation has been opened to assess the alleged defect.


 

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