EV System May Switch into Neutral Unexpectedly – 2019-2022 Gillig Low Floor Electric Transit Buses

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June 17, 2022 NHTSA CAMPAIGN NUMBER: 22V436000

EV System May Switch into Neutral Unexpectedly

An unexpected switch to neutral can cause a loss of vehicle propulsion and increase the risk of a crash.

 

NHTSA Campaign Number: 22V436

Manufacturer Gillig, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 169

 

Summary

Gillig, LLC (Gillig) is recalling certain 2019-2022 Low Floor electric transit buses. The EV resolver cable connector may experience a loss of electrical connectivity, unexpectedly switching from Drive to Neutral with no warning.

 

Remedy

Dealers will install a redesigned resolver cable with extended length and a new support bracket, free of charge. Owner notification letters were mailed on August 3, 2022. Owners may contact Gillig’s customer service at 1-510-264-5073 or 1-800-735-1500.

 

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.

 


Gillig has decided that certain model year 2019 through 2022 Low Floor battery electric buses, manufactured between 05/29/2019 and 04/08/2022 contain a defect related to motor vehicle safety. The affected vehicles may experience unexpected transition from Drive to Neutral mode while the vehicle is in motion with consequent loss of propulsion. The defect is due to loss of electrical continuity of the resolver cable connector. When the signal is lost, the EV control system immediately actuates a switch from Drive to Neutral mode with no advanced warning to the driver. An unexpected switch to neutral can cause a loss of vehicle propulsion and increase the risk of a crash.

As a result of the above, GILLIG has decided to voluntarily initiate a safety recall campaign of the vehicle population that may be affected by the issue.

 


Chronology :

On 3/4/2022 GILLIG Service received the first report of a vehicle switching unexpectedly from Drive to Neutral mode.

Between 3/4 and 3/24 GILLIG received seven (7) additional reports related to the same issue

On 4/4/2022 GILLIG engineering initiated the analysis of the external and internal EV system cables with support of the propulsion system manufacturer Cummins.

05/24/2022 GILLIG confirmed the root cause of the issue through vehicle testing and decided to design a new longer cable and a new support bracket to provide more robust connector strain relief.

On 6/10/2022 based upon the information developed during the investigation, the GILLIG Safety Committee decided to conduct a safety campaign to address this issue.

On 6/17/2022 GILLIG completed population analysis and identified 169 vehicles that may be affected by this defect.

On 06/17/2022 GILLIG filed a safety recall with NHTSA

 


4 Affected Products

Vehicle

MAKE MODEL YEAR
GILLIG LOW FLOOR 2019-2022

 


6 Associated Documents

Defect Notice 573 Report

RCLRPT-22V436-6412.PDF 215.607KB

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Recall Acknowledgement

RCAK-22V436-2125.pdf 646.058KB

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V436-2002.PDF 211.124KB

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V436-5513.PDF 211.224KB

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Issued Owner Notification Letter (Part 577)

RCONL-22V436-3618.pdf 72.006KB

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V436-9982.PDF 211.307KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V436&docType=RCL

 


 

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Last update on 2024-06-10 / Affiliate links / Images from Amazon Product Advertising API

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