23501 Insufficient Roof Panel Joint Strength – 2022-2024 IC Bus CE, 2022-2023 IC CE SBus, IC RE, & 2023 EV School Buses

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February 10, 2023 NHTSA CAMPAIGN NUMBER: 23V065000

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: 23V065

Manufacturer Navistar, Inc.

Components STRUCTURE

Potential Number of Units Affected 12,507

 

Summary

Navistar, Inc. (Navistar) is recalling certain 2022-2024 IC Bus CE, 2022-2023 IC CE SBus, IC RE, and 2023 EV school 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 23501.

 

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.

 


23501
APRIL 2023

NONCOMPLIANCE RECALL
Roof Lining Joints on certain 2022 thru 2024 IC Bus® CE and RE Series school bus models and 2023 IC Bus® Electric CE Series school bus models built 09/01/2021 thru 01/12/2023.

 

DEFECT DESCRIPTION

Certain school buses may not conform to Federal Motor Vehicle Safety Standard (FMVSS) 221 – The roof lining joints may not meet the required joint strength pull test requirement. A school bus roof panel with insufficient joint strength may separate during a crash, increasing the risk of injury.

 

MODELS INVOLVED

This noncompliance recall involves certain 2022 thru 2024 IC Bus® CE and RE Series school bus models and 2023 IC Bus® Electric CE Series school bus models built 09/01/2021 thru 01/12/2023.

 

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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.

 


8 Affected Products

Vehicles

MAKE MODEL YEAR
IC BUS CE 2022-2024
IC BUS CE SBUS 2022-2023
IC BUS EV 2023
IC BUS RE 2022-2023

 


5 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-23V065-2221.PDF 217.058KB

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Recall Acknowledgement

RCAK-23V065-3910.pdf 645.737KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V065-7947.pdf 46.572KB

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Remedy Instructions and TSB

RCRIT-23V065-4342.pdf 340.291KB

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Recall Quarterly Report #3, 2023-4

RCLQRT-23V065-9671.PDF 211.462KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V065&docType=RCL

 


 

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