R24-02 – Liquid in Battery Packs May Cause Fire – 2021-2023 New Flyer XE35, XE40, 2021-2024 XE60, & 2023-2024 XHE40

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January 31, 2024 NHTSA CAMPAIGN NUMBER: 24V056000

Liquid in Battery Packs May Cause Fire

The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.

 

NHTSA Campaign Number: 24V056

Manufacturer New Flyer of America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 337

 

Summary

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40, 2021-2024 XE60, and 2023-2024 XHE40 vehicles. One or more drain valves may not activate as intended, which could allow battery packs to accumulate liquid in the battery pack enclosure.

 

Remedy

New Flyer will remove the rubber washer from the affected drain valves, free of charge. Owner notification letters are expected to be mailed March 15, 2024. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer’s number for this recall is R24-02. This recall is in addition to NHTSA recall number 23V-083. Certain vehicles are affected by both recalls and will need to have both remedies performed.

 

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.

 


ITS: 60913
January 25, 2024

SUBJECT:
Version 2 drains in the ESS compartments will not deploy when required.

ISSUE:
The dissolving powder washer in the version 2 drains is not working correctly.

SUMMARY:
Inspect for version 2 drains and rework them to remove the washer and reinstall them. Mark the reworked drains with a green paint marker.

 

ITS60913

 

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Chronology :

September 2023, a drain valve for the ESS assembly was released which had a washer added to the face of the “bobbin” (internal component which reacts to liquid exposure). This was added to inhibit nuisance activation of the drain valve during times of high humidity and temperature.

December 2023, testing was being performed on an ESS assembly to validate liquid level calculations vs physical testing prior to drain valve activation. This testing indicated a less than optimal activation time of some of the drain valves.

December 2023/January 2024 testing and analysis continued on the delayed activation experienced from the drain valve and was ultimately determined the washer added to inhibit nuisance activation was impeding the bobbin from full function within a reasonable timeframe.

This issue was reviewed by the Vehicle Safety Committee during a special meeting on January 25, 2024, where the need for a recall was concurred, culminating in this 573 filing.

 


12 Affected Products

Vehicles

MAKE MODEL YEAR
NEW FLYER XE35 2021-2023
NEW FLYER XE40 2021-2023
NEW FLYER XE60 2021-2024
NEW FLYER XHE40 2023-2024

 


4 Associated Documents

Recall 573 Report – 02/08/2024

RCLRPT-24V056-5330.PDF 216.036KB

 


Defect Notice 573 Report

RCLRPT-24V056-4866.PDF 216.01KB

 


Recall Acknowledgement

RCAK-24V056-6536.pdf 746.069KB

 


Remedy Instructions and TSB

RCRIT-24V056-6760.pdf 428.201KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V056&docType=RCL

 


 

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Last update on 2024-02-07 / Affiliate links / Images from Amazon Product Advertising API

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