R-0002 – Electric Park Brake May Fail and Cause Rollaway – 2023 Lordstown Endurance

SEOCONTENT-START

Service procedure for R&R Rear Brake Caliper Assemblies
•
Turn on the vehicle, push the brake pedal and press the start/stop switch go to system ready, and select D on PRNDL. Move the vehicle onto the hoist and raise the hoist.
•
Release park brakes manually by using the park brake switch.
•
Get out of the vehicle and disconnect the Park brake connectors on Rear left and rear right calipers, then transition vehicle to OFF power mode.
•
Insert a blunt-ended bar (“pedal prop”) between driver’s seat and brake pedal, and adjust driver’s seat position such that the brake pedal is pushed 1” to 2” from it’s normal home position (this will greatly reduce the amount of brake fluid lost when the rear brake hoses are disconnected).
1
Service procedure for R&R Rear Brake Caliper Assemblies
•
Disconnect the 12V battery. Please Refer to the document: 12V disconnect procedure.
•
Remove lug nuts and wheel/tire assembly.
•
Disconnect HV lines on the inverter side. 2
Service procedure for R&R Rear Brake Caliper Assemblies
•
Disconnect the ground connections at the motor stator.
•
Disconnect the Temperature sensor on the motor stator.
•
Disconnect the brake jounce hose to brake line. Place a dripping pan to avoid any spills of brake fluid on the floor. 3
Service procedure for R&R Rear Brake Caliper Assemblies
4
• Detach coolant connections on the motor stator. Place a dripping pan to avoid any spills of coolant
on the floor.
• Remove the Dust covers on the motor. Align the holes on motor rotor and motor stator to install the
Brake service tools (BST).
Service procedure for R&R Rear Brake Caliper Assemblies
•
Position wheel assist lift under hub motor and adjust height to support hub motor assembly.
•
Remove 3 countersunk screws that attach motor rotor to bearing hub.
•
Remove the 8bolts securing the rear knuckle to motor stator.
5
•
Install the 4 provided M6X1.0 jack screws in the indicated holes on the rear knuckle until increased turning resistance is felt. Tighten each screw in one turn increments to separate motor assembly from rear knuckle.
•
Remove the caliper bolts and slide out the brake caliper.
•
Red Tag the caliper and ship it to back to LMC. Do not use it again.
Service procedure for R&R Rear Brake Caliper Assemblies
6
Service procedure for R&R Rear Brake Caliper Assemblies
Assembly:
•
Assemble the motor corner with new rear caliper. Remember to use new brake jounce hose AEEK-043-BB on the Rear left caliper and AEEK-044-BB on the rear right caliper.
•
Assembly is reverse of removal process. Please refer to the document for the assembly instructions Hub motor installation HM7.1-12.1 Knuckle Sub Assembly .xlsx.
•
install the motor assembly to the axle. Please refer to the document A-CHS01-009_WIP-02202023.pptx
•
After all the connections are restored Perform the following bleed procedure on brake system:
Two-person method:
1.
Fill brake fluid reservoir to the MAX mark. Elevate and secure vehicle
2.
Person 1 removes pedal prop from brake pedal.
3.
Person 2 instructs Person 1 to “Pump and Hold”.
4.
Person 1 presses and releases brake pedal 3 times, then presses and holds brake pedal.
5.
Person 1 says “Holding” loud enough for Person 2 to hear them.
6.
Person 2 loosens REAR LEFT bleed screw and allows brake fluid plus trapped air to escape.
7.
When brake pedal stops, Person 1 says “Floor” loud enough for Person 2 to hear.
8.
Person 2 tightens REAR LEFT bleed screw, then says “Sealed” loud enough for Person 1 to hear.
9.
Person 1 removes foot from brake pedal and says “Released” loud enough for Person 2 to hear.
10.
The team repeats steps 3 through 9 until no more air escapes from REAR LEFT bleed screw.
11.
Fill brake fluid reservoir to the MAX mark.
12.
The team repeats steps 3 through 11 at the FRONT LEFT bleed screw.
13.
The team repeats steps 3 through 11 at the FRONT RIGHT bleed screw.
14.
The team repeats steps 3 through 11 at the REAR RIGHT bleed screw.
•
Contact LMC to Perform commissioning/calibration of motor and thermal systems. 7

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Lordstown EV Corporation 2300 Hallock Young Rd., Suite 200, Warren, OH 44481
XXXXX, 2023
IMPORTANT SAFETY RECALL
This notice applies to your vehicle: XXXXXXXX
Dear XXXXX:
This notice is being sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Lordstown EV Corporation (“Lordstown”, “we”, or “us”) has decided that a defect, which relates to motor vehicle safety, exists in certain Model Year 2023 Lordstown Endurance vehicles. Our records indicate that your vehicle is included in the affected population of vehicles.
We apologize for this situation and look forward to working diligently to correct this issue.
What is the issue?
On your vehicle, an electric park brake (“EPB”) may lose clamping force over time due to a defective washer.
What is the risk?
If clamping force is lost, then the EPB could fail to prevent the vehicle from rolling when parked on a high grade. This could result in an increased risk of a crash.
What will Lordstown do?
Lordstown will replace each of the rear brake caliper assemblies on your vehicle at no charge to you. The repair is expected to take about 7.5 hours to complete.
What are your next steps?
If Lordstown has not already performed this repair, please contact Lordstown at 1-855-RIDE-LMC (1-855-743-3562) or customerservice@lordstownmotors.com to schedule an appointment for Lordstown to perform this repair.
What if you no longer own this vehicle?
If you no longer own your vehicle, and have an address for the current owner, please forward this letter to the new owner and also let us know that you no longer own the vehicle.
Do you have additional questions or concerns?
Please do not hesitate to reach out to us at 1-855-RIDE-LMC (1-855-743-3562) or customerservice@lordstownmotors.com to discuss any questions or concerns you have.
For additional information, please visit NHTSA.gov/recalls. If you are having difficulty getting your vehicle repaired in a reasonable time or without charge, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C.
XXXXX, 2023
Page 2
Federal law requires that you forward a copy of this safety recall notice to the lessee, if any, within 10 days.
Again, we apologize for any inconvenience, but are sincerely interested in your experience with your Lordstown Endurance and your safety. Thank you for your prompt attention to this matter.
Sincerely,
Lordstown EV Corporation
20590, or call the toll-free Vehicle Safety Hot Line at 1-888-327-4236 (TTY: 1-800-424-9153) or visit www.safercar.gov.

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-144
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lordstown EV Corp MAR 22, 2023 NHTSA Recall No. : 23V-144 Manufacturer Recall No. : R-0002 Manufacturer Information :
Manufacturer Name : Lordstown EV Corp Address : 38555 Hills Tech Dr
Farmington Hills MI 48331
Company phone : 248-522-9100
Population :
Number of potentially involved : 7
Estimated percentage with defect : 2 %
Vehicle Information : Vehicle 1 : 2023-2023 Lordstown Endurance Vehicle Type : LIGHT VEHICLES Body Style : PICKUP TRUCK Power Train : HYBRID ELECTRIC
Descriptive Information : Full-size electric pick-up truck. The recall includes vehicles built using parts from batches that may include electric park brake calipers with affected thrust washers.
Production Dates : NOV 07, 2022 – DEC 07, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The electric park brake calipers “EPB” may have been built with washers that had not been properly heat treated by the supplier. As a result, these washers could wear excessively over time, eventually leading the EPB to lose effectiveness and clamping force at grade.
Applicable Part Nos.: LEVC Part No. AEED-005-BA and AEEE-006-BA
FMVSS 1 :
FMVSS 2 :
Description of the Safety Risk : Description of the Cause :
NR NR
The clamping force of the EPB may degrade over time, which could allow the vehicle to roll after being parked, especially if on a high grade, which could increase the risk of a crash.
NR
Identification of Any Warning
that can Occur :
There are no prior warnings that could occur. Part 573 Safety Recall Report 23V-144 Page 2 Involved Components : Component Name 1 : Rear Brake Caliper Assembly Component Description : Rear Electric Park Brake Assembly Component Part Number : AEED-005-BA and AEEE-006-BA Component Name 2 : Rear Brake Caliper Thrust Washer Component Description : Thrust Washer
Component Part Number : Akebono Part No. 51-B5102-67320-00 Supplier Identification : Component Manufacturer
Name : Akebono Brake Corporation Address : 34385 W. Twelve Mile Rd.
Farmington Hills Michigan 48331
Country : United States Chronology :
On February 20, 2023, Lordstown EV Corporation (“Lordstown”) was notified by its supplier (Akebono) that certain rear electric park brake calipers (“EPBs”) delivered to Lordstown between November 4, 2022 and February 8, 2023 potentially contain affected thrust washers. Akebono advised Lordstown that its supplier of rear caliper thrust washers (JTEKT) notified Akebono of a potential hardness issue involving these washers in early February 2023 and the sub-supplier conducted an investigation from February 16 – 20 wherein it concluded that a small percentage of washers had not undergone proper heat treatment. Lordstown performed its analysis of reports and data provided by Akebono and considered the data provided, including the testing results. On March 1, 2023, Lordstown decided to conduct a recall to address this issue. Lordstown has not received any reports of accidents or injuries related to this issue. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-144
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Lordstown will replace the EPBs in affected vehicles at no cost to owners.
This part is covered under the vehicle warranty program, and reimbursement for a pre-notification remedy under 29 C.F.R. 573.13 and Part 577.11 is not necessary. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Akebono has determined that the affected EPBs are uniquely marked and are traceable and has provided Lordstown with the shipment IDs of the EPBs with potentially affected washers. Remedy components are marked with a unique marking (green square).
Only corrected EPBs that use washers that have been appropriately heat treated will be used in future production. All vehicles at the factory with affected EPBs will be retrofitted with corrected EPBs.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : MAR 03, 2023 – MAR 10, 2023
Planned Owner Notification Date : MAR 03, 2023 – MAR 10, 2023
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-144
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lordstown EV Corp APR 05, 2023 NHTSA Recall No. : 23V-144 Manufacturer Recall No. : R-0002 Manufacturer Information :
Manufacturer Name : Lordstown EV Corp Address : 38555 Hills Tech Dr
Farmington Hills MI 48331
Company phone : 248-522-9100
Population :
Number of potentially involved : 7
Estimated percentage with defect : 2 %
Vehicle Information : Vehicle 1 : 2023-2023 Lordstown Endurance Vehicle Type : LIGHT VEHICLES Body Style : PICKUP TRUCK Power Train : HYBRID ELECTRIC
Descriptive Information : Full-size electric pick-up truck. The recall includes vehicles built using parts from batches that may include electric park brake calipers with affected thrust washers.
Production Dates : NOV 07, 2022 – DEC 07, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The electric park brake calipers “EPB” may have been built with washers that had not been properly heat treated by the supplier. As a result, these washers could wear excessively over time, eventually leading the EPB to lose effectiveness and clamping force at grade.
Applicable Part Nos.: LEVC Part No. AEED-005-BA and AEEE-006-BA
FMVSS 1 :
FMVSS 2 :
Description of the Safety Risk : Description of the Cause :
NR NR
The clamping force of the EPB may degrade over time, which could allow the vehicle to roll after being parked, especially if on a high grade, which could increase the risk of a crash.
NR
Identification of Any Warning
that can Occur :
There are no prior warnings that could occur. Part 573 Safety Recall Report 23V-144 Page 2 Involved Components : Component Name 1 : Rear Brake Caliper Assembly Component Description : Rear Electric Park Brake Assembly Component Part Number : AEED-005-BA and AEEE-006-BA Component Name 2 : Rear Brake Caliper Thrust Washer Component Description : Thrust Washer
Component Part Number : Akebono Part No. 51-B5102-67320-00 Supplier Identification : Component Manufacturer
Name : Akebono Brake Corporation Address : 34385 W. Twelve Mile Rd.
Farmington Hills Michigan 48331
Country : United States Chronology :
On February 20, 2023, Lordstown EV Corporation (“Lordstown”) was notified by its supplier (Akebono) that certain rear electric park brake calipers (“EPBs”) delivered to Lordstown between November 4, 2022 and February 8, 2023 potentially contain affected thrust washers. Akebono advised Lordstown that its supplier of rear caliper thrust washers (JTEKT) notified Akebono of a potential hardness issue involving these washers in early February 2023 and the sub-supplier conducted an investigation from February 16 – 20 wherein it concluded that a small percentage of washers had not undergone proper heat treatment. Lordstown performed its analysis of reports and data provided by Akebono and considered the data provided, including the testing results. On March 1, 2023, Lordstown decided to conduct a recall to address this issue. Lordstown has not received any reports of accidents or injuries related to this issue. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-144
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Lordstown will replace the EPBs in affected vehicles at no cost to owners.
This part is covered under the vehicle warranty program, and reimbursement for a pre-notification remedy under 29 C.F.R. 573.13 and Part 577.11 is not necessary. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Akebono has determined that the affected EPBs are uniquely marked and are traceable and has provided Lordstown with the shipment IDs of the EPBs with potentially affected washers. Remedy components are marked with a unique marking (green square).
Only corrected EPBs that use washers that have been appropriately heat treated will be used in future production. All vehicles at the factory with affected EPBs will be retrofitted with corrected EPBs. Recall Schedule :
Description of Recall Schedule : Written notification has been sent to all affected owners; dealer notified.
Notification is complete.
Planned Dealer Notification Date : MAR 03, 2023 – MAR 10, 2023
Planned Owner Notification Date : MAR 03, 2023 – MAR 10, 2023
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-144
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Lordstown EV Corp MAR 03, 2023 NHTSA Recall No. : 23V-144 Manufacturer Recall No. : R-0002 Manufacturer Information :
Manufacturer Name : Lordstown EV Corp Address : 38555 Hills Tech Dr
Farmington Hills MI 48331
Company phone : 248-522-9100
Population :
Number of potentially involved : 5
Estimated percentage with defect : 2 %
Vehicle Information : Vehicle 1 : 2023-2023 Lordstown Endurance Vehicle Type : LIGHT VEHICLES Body Style : PICKUP TRUCK Power Train : HYBRID ELECTRIC
Descriptive Information : Full-size electric pick-up truck. The recall includes vehicles built using parts from batches that may include electric park brake calipers with affected thrust washers.
Production Dates : NOV 07, 2022 – DEC 07, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The electric park brake calipers “EPB” may have been built with washers that had not been properly heat treated by the supplier. As a result, these washers could wear excessively over time, eventually leading the EPB to lose effectiveness and clamping force at grade.
Applicable Part Nos.: LEVC Part No. AEED-005-BA and AEEE-006-BA
FMVSS 1 :
FMVSS 2 :
Description of the Safety Risk : Description of the Cause :
NR NR
The clamping force of the EPB may degrade over time, which could allow the vehicle to roll after being parked, especially if on a high grade, which could increase the risk of a crash.
NR
Identification of Any Warning
that can Occur :
There are no prior warnings that could occur. Part 573 Safety Recall Report 23V-144 Page 2 Involved Components : Component Name 1 : Rear Brake Caliper Assembly Component Description : Rear Electric Park Brake Assembly Component Part Number : AEED-005-BA and AEEE-006-BA Component Name 2 : Rear Brake Caliper Thrust Washer Component Description : Thrust Washer
Component Part Number : Akebono Part No. 51-B5102-67320-00 Supplier Identification : Component Manufacturer
Name : Akebono Brake Corporation Address : 34385 W. Twelve Mile Rd.
Farmington Hills Michigan 48331
Country : United States Chronology :
On February 20, 2023, Lordstown EV Corporation (“Lordstown”) was notified by its supplier (Akebono) that certain rear electric park brake calipers (“EPBs”) delivered to Lordstown between November 4, 2022 and February 8, 2023 potentially contain affected thrust washers. Akebono advised Lordstown that its supplier of rear caliper thrust washers (JTEKT) notified Akebono of a potential hardness issue involving these washers in early February 2023 and the sub-supplier conducted an investigation from February 16 – 20 wherein it concluded that a small percentage of washers had not undergone proper heat treatment. Lordstown performed its analysis of reports and data provided by Akebono and considered the data provided, including the testing results. On March 1, 2023, Lordstown decided to conduct a recall to address this issue. Lordstown has not received any reports of accidents or injuries related to this issue. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-144
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Lordstown will replace the EPBs in affected vehicles at no cost to owners.
This part is covered under the vehicle warranty program, and reimbursement for a pre-notification remedy under 29 C.F.R. 573.13 and Part 577.11 is not necessary. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : Akebono has determined that the affected EPBs are uniquely marked and are traceable and has provided Lordstown with the shipment IDs of the EPBs with potentially affected washers. Remedy components are marked with a unique marking (green square).
Only corrected EPBs that use washers that have been appropriately heat treated will be used in future production. All vehicles at the factory with affected EPBs will be retrofitted with corrected EPBs.
Recall Schedule :
Description of Recall Schedule : NR
Planned Dealer Notification Date : MAR 03, 2023 – MAR 10, 2023
Planned Owner Notification Date : MAR 03, 2023 – MAR 10, 2023
* NR – Not Reported

SEOCONTENT-END