Rear Axle Drive Pinion May Fracture – 2021-2022 Spartan Gladiator, MetroStar, & MetroStar-RT

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January 20, 2022 NHTSA CAMPAIGN NUMBER: 22V019000

Rear Axle Drive Pinion May Fracture

A fractured drive pinion may contact the brake drop hose, and unintentionally engage the parking brake without detection, or without the brake lights activating, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V019

Manufacturer Marion Body Works Inc.

Components POWER TRAIN

Potential Number of Units Affected 11

 

Summary

Marion Body Works Inc. (Marion Body Works) is recalling certain 2021-2022 Spartan Gladiator, MetroStar, and MetroStar-RT vehicles equipped with MeritoreBay 180 series drive pinions. The rear axle drive pinion may fracture.

 

Remedy

MeritoreBay will inspect and replace the drive pinion, as necessary, free of charge. Owner notification letters were mailed January 28, 2022. Owners may contact Marion Body Works customer service at 1-715-754-5261. Marion Body Works number for this recall is 21V-899.

 

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.

 


Spartan FireeBay, LLC has decided that a defect which relates to motor vehicle safety exists in certain model year 2021-2022 Gladiator, MetroStar, and MetroStar-RT model emergency response chassis cabs equipped with MeritoreBay Series 180 Axle Pinion Shaft.

 

What is the defect?

It has been reported that some MeritoreBay drive pinion 180 series axles may be fractured in the pinion spline.
If this defect exists, the fracturing of the pinion may hit the brake drop hose which may unintentionally apply the parking brake without detection or brake lights coming on, increasing the risk of a crash. The issue could occur without warning.

 

What is the manufacturer doing?

A MeritoreBay representative will contact you to schedule the axle pinion inspection and repair as needed. The inspection will need to be performed with a service technician and MeritoreBay representative. The inspection will take approximately 1 hour. If it is determined that the pinion is fractured, MeritoreBay will inform you and Spartan that the Differential CarriereBay Housing Assembly will need to be replaced. MeritoreBay and Spartan will help locate an authorized service facility if you are unable to complete the replacement of the assembly once it is received. The repair will take approximately five hours to complete. There is no cost to the vehicle owner for the recall remedy.

 

What should you do?

A MeritoreBay representative will contact you to have the inspection scheduled at a service center nearest to you and completed at no charge.

If you have any questions or concerns, please contact:

Spartan Warranty โ€“ P: 800-867-6478
Marion Body Works โ€“ Fire & Emergency Warranty โ€“ P: 715-754-5261

 


Chronology :

June 2020 โ€“ Pinion crack found on campus in Charlotte during a different PSR.

August โ€“ September 2020 – They completed tests to attempt to replicate and could not reproduce the fracture.
Implemented 100% mag particle inspection on all 186R series. MeritoreBay Product Engineering provided a high confidence level that this would be an infancy failure (during the carriers first high load event) due to the fracture signature.

April 2021 โ€“ Claim created through standard warranty process for pinion crack.

July 2021 โ€“ Pinion failure during delivery to the dealer from the plant. Facilitated warranty claim through MeritoreBay, they provided new gear set.

September 2021 โ€“ Houston reached out regarding a pinion crack failure while in service (24 hours in service and under 3,000 miles), was second truck of fleet with similar failure. Pinion broke off and damaged the spring brake air supply line. Metro and Houston insisted an inspection method to validate that the rest of the fleet do not have the same failures. This resulted in MeritoreBay completing an on-site ultrasonic test for the rest of the fleet. MeritoreBay provided corrective action and containment dates, as well as their assessment that this issue is low risk.

October 2021 โ€“ Spartan risk assessment completed.

October โ€“ November 2021 โ€“ Reviewed past precedence. Reached out to all REV Fire businesses to check for any MeritoreBay pinion warranty issues. E-OneeBay had one failure in the field in October 2021 but a different axle series affected. Met with MeritoreBay to review the cause again and the potential affected population.

November 10, 2021 โ€“ Escalated the issue to REV Group Management.

November 15, 2021 โ€“ REVโ€™s senior leadership approved a voluntary recall for this issue.

 


4 Affected Products

Vehicles

MAKEMODELYEAR
SPARTAN FIREeBayGLADIATOR2021-2022
SPARTAN FIREeBayMETROSTAR2021-2022

 


7 Associated Documents

Recall Acknowledgement

RCAK-22V019-6831.pdf 645.231KB

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Defect Notice 573 Report

RCLRPT-22V019-4080.PDF 215.79KB

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Recall 573 Report- 04/18/2022

RCLRPT-22V019-2282.PDF 215.792KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-22V019-4755.PDF 239.325KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-22V019-8549.PDF 211.229KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-22V019-1642.PDF 211.307KB

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Owner Notification Letter(Part 577)

RCONL-22V019-4811.pdf 112.171KB

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