23502 Insufficient Roof Panel Joint Strength – 2022-2023 IC Bus CE, & 2022-2023 IC RE Transit Buses

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February 10, 2023 NHTSA CAMPAIGN NUMBER: 23V066000

Insufficient Roof Panel Joint Strength/FMVSS 221

A school bus roof panel with insufficient joint strength may separate during a crash, increasing the risk of injury.

 

NHTSA Campaign Number: 23V066

Manufacturer Navistar, Inc.

Components STRUCTURE

Potential Number of Units Affected 115

 

Summary

Navistar, Inc. (Navistar) is recalling certain 2022-2023 IC Bus CE, and 2022-2023 IC RE transit buses. The roof panel may have been manufactured with insufficient joint strength. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 221, “School Bus Body Joint Strength.”

 

Remedy

Dealers will add additional fasteners to secure the joints, free of charge. Owner notification letters are expected to be mailed April 3, 2023. Owners may contact Navistar’s customer service at 1-800-448-7825. Navistar’s number for this recall is 23502.

 

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.

 


23502
APRIL 2023

 

DEFECT DESCRIPTION

One or more joints that connect the roof top sheets may have not been properly secured to the roof bow supports. In the event of an accident involving the roof of the bus, the roof top sheets may separate and not protect the occupants sufficiently, increasing the risk of possible injury or death.

 

MODELS INVOLVED

This safety recall involves certain 2022 and 2023 IC Bus® CE and RE Series commercial bus models built 09/01/2021 thru 12/15/2022.

 

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Chronology :

  • 01/19/2023 – Navistar Manufacturing initiated an investigation of a leaking roof at water test and noticed insufficient overlap of the roof sheeting.
  • 01/19/2023 and 01/20/2023 – Navistar Manufacturing audits the processes from bow former through topping sheet installation.
  • 01/24/2023 – Navistar Manufacturing quarantines buses at the assembly plant and contains the issue in manufacturing.
  • 1/25/2023 When testing compliance to FMVSS 221, Navistar pull tests of three suspect roof joints did not meet the 6,241 pound pull test requirement. Joints separated at 5,645 and 5,026 pounds.
  •  01/31/2023 – Navistar Manufacturing meets with Compliance to review pull test results and initiate investigation to determine the impact to IC buses.
  • 02/02/2023 – Navistar determines the suspect population and declares a Non Compliance recall.
  • 03/02/2023 – Navistar reclassifies 23502 to a safety recall based on determination by Navistar Compliance and Certification Compliance that FMVSS 221 and CMVSS 221 apply to school bus only.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
IC BUS CE 2022-2023
IC BUS RE 2022-2023

 


6 Associated Documents

Recall Acknowledgement

RCAK-23V066-8598.pdf 645.702KB

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Noncompliance Notice 573 Report

RCLRPT-23V066-7954.PDF 214.502KB

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Recall 573 Report – March 9, 2023

RCLRPT-23V066-6731.PDF 214.452KB

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Remedy Instructions and TSB

RCRIT-23V066-4607.pdf 346.952KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V066-1496.pdf 47.376KB

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Recall Quarterly Report #3, 2023-4

RCLQRT-23V066-2602.PDF 211.444KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V066&docType=RCL

 


 

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