Tag Axle May Become Misaligned – 2018-2020 MCI D4505 & D4500 Coaches

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December 27, 2019 NHTSA CAMPAIGN NUMBER: 19V924000

Tag Axle May Become Misaligned

If the tag axle becomes misaligned with the front of the vehicle, the rear of the vehicle may strike other vehicles or pedestrians, increasing the risk of a crash or injury.

 

NHTSA Campaign Number: 19V924

Manufacturer Motor Coach Industries

Components SUSPENSION

Potential Number of Units Affected 276

 

Summary

Motor Coach Industries (MCI) is recalling certain 2018-2020 D4505 and D4500 coaches equipped with an optional steerable tag axle. The tag axle mounting block clamps that retain the tie rod to obtain the forward steer orientation may slip, resulting in the tag axle being out of alignment.

 

Remedy

MCI will notify owners, and dealers will replace the block clamps and retorque the fasteners, free of charge. The recall began February 19, 2020. Owners may contact MCI customer service at 1-800-241-2947.

 

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.safercar.gov.

 


Subject: Tag Axle Lock Clamps Rework
Field Change Program: Field Campaign FCP Number: 477 Revision:  A Date: 02/18/2020
Coach Section:  12- Suspension P/N: 12-04-1253 Type: Safety Recall

 

Ref. NHTSA Recall No.: 19V-924 Ref. Transport Canada Recall No.: N/A

 

Application:

Coach Model Model Year UNIT
D4500 & D4505 2018 – 2020 15097 – 15119, 15149 – 15196, 15204 – 15207, 15260, 15263, 15266, 15269, 15271, 15274, 15322 – 15324, 15348 – 15358, 15376, 15377, 15426, 15430 – 15432, 15439, 15449, 15450, 15456 – 15465, 15467 – 15474, 15477 -15479, 15532 – 15564, 15583, 15584, 15595 – 15608, 15614 – 15618, 15621 – 15707, 15709 –  15715, 15717, 15718, 15720

 

WARNING

Read this entire procedure before beginning work. 

Use Safe Shop Practices at All Times.

To avoid personal injury:

  1. Proper Personal Protective Equipment (PPE) must be worn. Safety glasses and protective gloves are required for working with DEF Fluid.
  2. Turn the main battery disconnect switch to the OFF position.
  3. Ensure that both the front and the rear wheels are chocked.
  4. Position the ENGINE RUN and ENGINE START switches on the engine compartment remote control box to the OFF
  5. Allow enough time for components to cool down prior to working in the engine compartment.

 

1.0 Description

Customer Complaint:

Motor Coach Industries (“MCI”) has become aware that on certain 2018 – 2020 D4500 and D4505 model coaches the tag axle steering locking plates mounted to the tag steering tire rod linkage may not be sufficiently clamped and may come loose, possibly resulting in the tag axle becoming unlocked while the coach is in operation.

 

Cause:

The causes of the insufficient clamping were determined to be (1) the clamp blocks having paint on the clamping surfaces, (2) the fastener surfaces on the clamp blocks not being machined, and (3) the fastener head surface not being perpendicular to the tie rod clamping surface. The combination of paint on the clamping surface and the fastener head side loading allowed the clamp fasteners to lose torque. This allowed the tie rod to slide in operation when under load. Movement of the tie rod within the lock clamps allowed the tag axle to be offset from the front steering axle.

 

Corrective Action:

MCI strongly recommends owners of the affected coaches have the following procedure performed as soon as possible.

 

2.0 Material requirements

ITEM PART NO QTY U/M DESCRIPTION
1 19-1-1439 4 EA Capscrew- Hex, HD, 1/2NF-20X4.25
2 19-2-284 8 EA Washer-Flat, ½ ID, Steel, ZN Plated, GR8
3 19-3-366 4 EA Nut, ½-20WNF,GR8, STL Zinc PLT
4 12-04-1153 2 EA Clamp

 

3.0 Special Tools

3M Scotch Brite Abrasive sandpaper

Loctite 242 (MCI P/N: 21-7212-18)

Thread seal (MCI P/N: 15G-1-43)

Isopropyl Alcohol (MCI P/N: 23-05-0005)

 

4.0 Procedure

4.1 Removing the fasteners

Scribe the location of the clamp and lock plate on the tie rod.

Remove and discard the 4 nuts, bolts and washers securing the clamp to the lock assembly on tag axle. Discard the clamps.

Remove and save the nut, bolt, and washer securing the lock assembly and the damper.

 

Remove and save the 8 nuts and washers securing the tie plate to the lock assembly and to the axle. Save the tie plate and shims.

Slide the lock assembly and lock plate down and observe for paint on the lock plate at the location illustrated below. If paint is observed on the surface of the lock plate that clamps the tie rod, use an abrasive paper to remove the paint in that area.

 

4.2 Torqueing the fasteners

Clean the lock assembly plate with isopropyl alcohol, MCI P/N: 23-05-0005.

Re-install tie plate, lock plate, and lock assembly to the axle at the scribed location using existing nuts, bolts, washers and shims. Torque the nuts to 87 Ft-Lb.

 

CAUTION

Make sure to position the lock plate at the scribed location.

Re-install the damper to the lock assembly using existing hardware. Torque the nut to 87 Ft-Lb.

Clean the clamps, MCI P/N: 12-04-1153, with isopropyl alcohol, MCI P/N: 23-05-0005.

Install the clamps to lock assembly using nuts, MCI P/N: 19-3-366, washers, MCI P/N: 19-2-284, and bolts, 19-1-1439. Apply Loctite to the base threads of the bolts before securing the nuts. Hand tighten the nuts.

Torque the nuts as follows:

Torque fastener #1 to 15 Ft-Lb

Torque fastener #4 to 15 Ft-Lb

Torque fastener #2 to 15 Ft-Lb

Torque fastener #3 to 15 Ft-Lb

Repeat torqueing the fasteners in the same sequence incrementing torque by 15 Ft-Lb until you reach 75 Ft-Lb.

Apply thread seal once all the fasteners are torqued to 75 Ft-Lb.

 

5.0 Field Change Program Conditions:

The parts required for this change will be supplied without charge.

A labor allowance of 1 hours will be granted for the rework.

This labor allowance will be credited to your MCI Fleet Support Parts Account on receipt of the attached “MCI Field Change Program Verification Form” and a “Warranty Claim Form” as detailed in your Owner Warranty manual to MCI’s Warranty department. A “MCI Field Change Program Verification Form” needs to be submitted for each VIN affected. Photocopy the attached “MCI Field Change Program Verification Form” as required for the number of affected coaches in your fleet.

Motor Coach apologizes for any inconvenience resulting from this campaign but urges you to implement this change as soon as possible.

Sincerely,

Motor Coach Industries

 

5.1 MCI FIELD CHANGE PROGRAM (FCP) VERIFICATION

 

FAX TO: 800-360-8886 

 

Mail or fax the completed limited warranty claim form and verification form to MCI’s warranty department, or photocopy and mail to:

MCI Fleet Support

Attn: Warranty Department

7001 Universal Coach Drive Louisville, KY 40258

Fax Number 1-800-360-8886

To receive credit for the hours used to complete this task. Contact the MCI Fleet Support Technical Center at 1-800-241-2947 for any further information.

 


February 19, 2020

 

IMPORTANT SAFETY RECALL

This notice applies to your vehicle(s) [«UNIT»]

 

«CUST_NAME»
ATTENTION:  TECH SERVICE DEPT/MAINT
«ADDRESS_1»
«CITY», «STATE» «ZIP»

 

SUBJECT: SAFETY RECALL:  TAG AXLE LOCK CLAMPS
Ref.: NHTSA # 19V-924
MCI Service Bulletin 477

 

Attention Owner:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Motor Coach Industries, Inc. (“MCI”) has decided that a defect which relates to motor vehicle safety exists on certain MCI model year 2018 – 2020 D4500 and D4505 coaches equipped with a steerable tag axle.  The tag axle mounting block clamps that retain the tie rod to obtain the forward steer orientation may slip on the affected vehicles, resulting in the tag axle being out of alignment.  If the tag axle becomes misaligned with the front of the vehicle, the rear of the vehicle may strike other vehicles or pedestrians, increasing the risk of a crash or injury.

MCI is conducting a recall of the affected vehicles to repair the defect condition.  Please see the enclosed MCI Service Bulletin 477 for further information.  MCI is providing a service kit with replacement parts at no charge to owners of the affected vehicles, and labor reimbursement.  MCI estimates that it will take one hour to repair each affected vehicle.

MCI records indicate that you are the owner or operator of the following vehicle(s) included in this recall:

«Unit_Numbers»

 

MCI strongly urges you to have the recall work performed on your vehicle(s) as quickly as possible.

You may contact the MCI Customer Service Line at 1-800-241-2947 if you have any questions about this recall campaign or wish to make arrangements to have your vehicle(s) repaired at an authorized MCI service center.  Submittal of MCI Warranty Claim Forms may be completed on MCI’s website at https://fleetsupportiw.mcicoach.com/iwarranty/signon (click on Customer Care System), or a photocopy of the Warranty Claim Form found in the Warranty Manual can be mailed / faxed to the MCI Warranty Department.  Please refer to Service Bulletin 477, and your OWNER LIMITED WARRANTY MANUAL, for more detailed information.

After contacting MCI Customer Service, if you are still unable to have the safety defect remedied without charge and within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call 888 327-4236 (TTY: 800-424-9153), or go to https://www.safercar.gov, if remedy difficulties exist.

If you are the lessor of the vehicle(s) identified above, Federal law requires that you forward this notice by first class mail to the most recent lessee(s) known to you, within ten days of your receipt of this notice.

If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s).

If you had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement.  Please contact the MCI Customer Service Line at 1-800-241-2947 for further information in that regard.

We regret the inconvenience this may cause you, but urge you to implement the recall procedures with respect to your vehicle(s) as soon as possible for your added safety and satisfaction.

 

Sincerely,

Motor Coach Industries

Warranty Department

 

Enclosure: MCI Service Bulletin 477

 


6 Affected Products

Vehicles

MAKE MODEL YEAR
MCI D4500 2018-2020
MCI D4505 2018-2020

 


8 Associated Documents

Recall Quarterly Report #1, 2020-1

RCLQRT-19V924-0093.PDF 211.131KB

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Defect Notice 573 Report

RCLRPT-19V924-5565.PDF 214.8KB

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Recall Acknowledgement

RCAK-19V924-1182.pdf 287.651KB

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Recall 573 Report – Amendment 1

RCLRPT-19V924-2749.PDF 214.862KB

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Remedy Instructions and TSB

RCRIT-19V924-9173.pdf 571.491KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V924-7405.pdf 194.808KB

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Remedy Instructions and TSB

RCRIT-19V924-9060.pdf 762.59KB

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Recall Quarterly Report #3, 2020-3

RCLQRT-19V924-9517.PDF 211.308KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V924&docType=RCL

 


 

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