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August 2, 2023 NHTSA CAMPAIGN NUMBER: 23V541000
Headlight failure or incorrectly adjusted headlights can reduce visibility and increasing the risk of a crash.
NHTSA Campaign Number: 23V541
Manufacturer Hino Motors Sales U.S.A., Inc.
Components EXTERIOR LIGHTING
Potential Number of Units Affected 468
Summary
Hino Motors Sales U.S.A., Inc. (Hino) is recalling certain 2022-2023 NE7A, NJ7A, NJ7B and NV7A vehicles, equipped with headlights that are recessed in the hood. The headlight back covers, and anti-adjustment caps may have been improperly installed, which can result in headlight failure, or the headlights being adjusted incorrectly. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, “Lamps, Reflective Devices, and Associated Equipment.”
Remedy
Dealers will inspect the anti-adjustment caps and back covers. In addition, dealers will confirm the headlight aim, and install any missing caps or covers. All repairs will be performed free of charge. Owner notification letters are expected to be mailed October 3, 2023. Owners may contact Hino customer service at 1-248-699-9390. Hino’s number for this recall is M0430.
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.
Chronology of Defect Determination
July – August 2022
In late July 2022, during a shipping quality audit at its WV assembly plant, Hino discovered one vehicle where the anti-adjustment caps and back covers were not installed. Hino launched an investigation to determine the root cause of the missing caps and covers. Hino began with a check of all inventory vehicles equipped with LED Headlamps. Ultimately, 17 vehicles were inspected, and 4 vehicles had missing anti-adjustment caps or back covers. The root cause was unclear, therefore Hino continued to investigate.
September 2022-February 2023
Hino began a field survey to confirm the status of suspect trucks and identify the scope of the issue. Hino inspected vehicles and identified one additional occurrence of missing anti-adjustment cap on an LED equipped vehicle manufactured in October of 2021.
Hino also continued its analysis of the six vehicles it had discovered with missing caps and covers. From checking production history and process, Hino determined that all had undergone hood or headlamp replacement.
March 2023 – July 2023
Hino performed an audit at the Woodstock Ontario assembly plant to confirm the headlamp assembly and aiming process as well as their repair process. QA concluded that the Woodstock process was robust and that it was unlikely that the parts had failed to have been installed during the production or repair process.
Hino internal rule requires the use of a rebuild check sheet during the repair process, but the rule was neglected to be followed. After long term shutdown was finished in September 2021, The WV plant had implemented a new ATS (Automated Tracking System) to document vehicle production data. Due to confusion by the repair team, repairs were only documented in the ATS system, this created gaps in the repair process.
During this time, Hino also expanded its review. Hino trucks use two types of headlamps, LED and Halogen, the structure of the headlamps and adjustment lock out is different with each other, Hino continued investigation to confirm if the issue involved only trucks equipped with LED headlamps, or if Halogen vehicles repaired during the same time frame were also suspect. Upon reviewing repair records for Halogen headlamps, it concluded that those vehicles were also potentially affected.
Hino also investigated the effects of the missing anti-adjustment caps or back covers. It concluded that improper installation of the caps of each type of headlamp will lead to a possibility of incorrect adjustment of the horizontal beam by a customer. Additionally, Hino confirmed the wiring structure of both headlamps and found that water may potentially intrude through the headlamp circuit from the back of the headlamp assembly and cause a short circuit if the back cover is missing.
On July 26, 2023, based on the investigation result explained above, Hino determined that subject vehicles may not meet certain requirements of FMVSS No. 108 and to conduct a voluntary non-compliance recall campaign for the vehicles that had hood or headlamp replacement without standard rework procedure prior to shipment.
As of July 25, 2023, Hino is not aware of any reports of incidents or accidents relevant to this failure from either field reports or warranty data.
8 Affected Products
Vehicles
MAKE | MODEL | YEAR |
HINO | NE7A | 2022-2023 |
HINO | NJ7A | 2022-2023 |
HINO | NJ7B | 2022-2023 |
HINO | NV7A | 2022-2023 |
3 Associated Documents
Noncompliance Notice 573 Report
RCLRPT-23V541-4840.PDF 214.48KB
Recall Acknowledgement
RCAK-23V541-5794.pdf 645.387KB
Chronology of Defect Determination
RMISC-23V541-9633.pdf 115.677KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V541&docType=RCL
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- The Sylvania Standard Of Quality: With over 100 years in business, Sylvania is the world leader in automotive lighting for Original Equipment Manufacturers (OEMs) and the aftermarket.
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Last update on 2024-04-12 / Affiliate links / Images from Amazon Product Advertising API
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-541 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Hino Motors Sales U.S.A., Inc. Submission Date : AUG 02, 2023 NHTSA Recall No. : 23V-541 Manufacturer Recall No. : M0430 Manufacturer Information : Manufacturer Name : Hino Motors Sales U.S.A., Inc. Address : 45501 Twelve Mile Road Novi MI 48377 Company phone : 248-699-9300 Population : Number of potentially involved : 468 Estimated percentage with defect : 20 % Vehicle Information : Vehicle 1 : 2022-2023 Hino NE7A, NJ7A, NJ7B, NV7A Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : Power Train : DIESEL Descriptive Information : The recall population was determined by reviewing Hino production and repair records for vehicles which had hood or headlamp replacement because of quality concerns. The recall population consists of the vehicle models produced between September 3, 2021, and July 19, 2022. Although all the involved vehicles are within the above production period range, not all vehicles in this range had their hoods replaced. This recall excludes vehicles that were not originally equipped with hoods or headlamps which have quality concerns or were repaired properly prior to shipment. Production Dates : SEP 03, 2021 – JUL 19, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : The subject vehicles are equipped with headlamps that are recessed in the hood. The underside of the hood has an opening for accessing the back of the headlamp assembly. This opening contains a back cover to protect the headlamp from water intrusion. In addition, the headlamp adjustment mechanism has an anti-adjustment cap to prevent a customer from having an opportunity to adjust the headlamp aim. There is a possibility that the back cover(s) and/or the anti-adjustment cap(s) may not have been properly installed. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR Description of the Safety Risk : Without an anti-adjustment cap, a customer may adjust the horizontal beam in violation of FMVSS No. 108, paragraphs S10.18.4. An incorrectly adjusted Part 573 Safety Recall Report 23V-541 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 beam may also decrease driver visibility, increasing the risk of a crash. Without the back cover, water may intrude which could cause a headlamp short circuit. If the headlamp shorts and becomes potentially inoperative it also impairs driver visibility and increases the risk of a crash. Description of the Cause : Due to non-standard work during hood or headlamp replacement because of quality concerns, there is a possibility that the back cover(s) and/or the antiadjustment caps(s) may not have been properly installed. Identification of Any Warning that can Occur : N/R Involved Components : Component Name 1 : Anti-adjustment Cap Component Description : Anti-adjustment Cap Component Part Number : 89279-E0340 Component Name 2 : Back Cover Component Description : Back Cover Component Part Number : S8111-61210 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : See attached Part 573 Safety Recall Report 23V-541 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : For all the subjected vehicles, the Hino dealer will inspect the presence of anti-adjustment cap(s) and back cover(s), and if missing, confirm headlamp aim, and install any missing cap(s) or cover(s), free of charge. Customers who have received the “Customer Notification Letter for Recall (M0430)”, who may have paid for repairs due to this defect may apply for reimbursement for those repair costs. All pre-notification reimbursement requests for repairs which were performed until a date 10 days after the final customer notification was made will be considered by Hino for reimbursement. Hino will also reimburse for all Parts, Labor, and miscellaneous costs directly related to the remedy of this defect. Requests for reimbursement, including paid receipts, should be directed to warranty@hino.com. How Remedy Component Differs from Recalled Component : There is no change between remedy and recalled components. Missing cap (s) and/or cover(s) will be equipped as designed. Identify How/When Recall Condition was Corrected in Production : July 26, 2022, ATS has been systematically updated to ensure that any truck identified as needing a hood or headlamp rework, will have headlamp adjustment checked and confirmation that all caps have been installed as designed. In addition, the rebuild check sheets utilized by repair have been updated to highlight headlamp adjustment and antiadjustment cap installation as regulatory items. Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : AUG 03, 2023 – AUG 03, 2023 Planned Owner Notification Date : OCT 03, 2023 – OCT 03, 2023 * NR – Not Reported
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