R23-20 – Transmission May Separate from Driveshaft – 2019-2024 New Flyer XD35, XD40, XN35, & XN40 Transit Buses

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October 26, 2023 NHTSA CAMPAIGN NUMBER: 23V722000

Transmission May Separate from Driveshaft

A sudden loss of drive power can increase the risk of a crash.

 

NHTSA Campaign Number: 23V722000

Manufacturer New Flyer of America, Inc.

Components POWER TRAIN

Potential Number of Units Affected 2,351

 

Summary

New Flyer of America, Inc. (New Flyer) is recalling certain 2019-2024 XD35, XD40, XN35, and XN40 transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.

 

Remedy

New Flyer will work with the equipment manufacturer, Allison Transmission Inc., to inspect, and if necessary, tighten loose transmission yoke bolts, free of charge. Owner notification letters are expected to be mailed November 30, 2023. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer’s number for this recall is R23-20.

 

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.

 


ITS60844
19-Oct-2023

SUBJECT:
Retorque Transmission Yoke as per Allison Document SIL 20-WT-23

ISSUE:
This is to inform you that your vehicle may be non-compliant with the requirements of the Motor Vehicle Safety Regulations and that the noncompliance could affect the safety of a person. Allison Transmission has observed a potential concern that affects the output shaft yoke/flange retaining bolt

SUMMARY:
As a Customer Satisfaction Initiative, Allison will support increasing the output shaft yoke/flange retaining bolt torque specification for B3400 R xFE™ and B400 R Series transmissions.

 

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Chronology :

New Flyer investigated reports of loose transmission yokes from a US based property, and in July/August 2023 requested the transmission supplier (Allison Transmission, Inc [ATI]) assist and review.

August/September, 2023, through checks that ATI performed on the subject buses, a higher-than-expected number of fasteners holding the yoke to the transmission output shaft were identified.

New Flyer and ATI continued discussions surrounding the cause, which led to ATI issuing an equipment recall (NHTSA, 23E079). New Flyer was made aware of this recall on October 17, 2023, and held several conference calls with Allison for additional details.

A review of the issue and ATI’s recall were the basis of a special meeting of New Flyer’s Safety Committee on October 23, 2023, and consensus determined New Flyer would issue a recall, culminating in this submission.

 


24 Affected Products

Vehicles

MAKE MODEL YEAR
NEW FLYER XD35 2019-2024
NEW FLYER XD40 2019-2024
NEW FLYER XN35 2019-2024
NEW FLYER XN40 2019-2024

 


3 Associated Documents

Recall Acknowledgement

RCAK-23V722-6757.pdf 704.291KB

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Defect Notice 573 Report

RCLRPT-23V722-9099.PDF 217.341KB

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Remedy Instructions and TSB

RCRIT-23V722-5965.pdf 1008.963KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V722&docType=RCL

 


 

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