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January 20, 2022 NHTSA CAMPAIGN NUMBER: 22V019000
Rear Axle Drive Pinion May Fracture
A fractured drive pinion may contact the brake drop hose, and unintentionally engage the parking brake without detection, or without the brake lights activating, increasing the risk of a crash.
NHTSA Campaign Number: 22V019
Manufacturer Marion Body Works Inc.
Components POWER TRAIN
Potential Number of Units Affected 11
Summary
Marion Body Works Inc. (Marion Body Works) is recalling certain 2021-2022 Spartan Gladiator, MetroStar, and MetroStar-RT vehicles equipped with Meritor 180 series drive pinions. The rear axle drive pinion may fracture.
Remedy
Meritor will inspect and replace the drive pinion, as necessary, free of charge. Owner notification letters were mailed January 28, 2022. Owners may contact Marion Body Works customer service at 1-715-754-5261. Marion Body Works number for this recall is 21V-899.
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.
Spartan Fire, LLC has decided that a defect which relates to motor vehicle safety exists in certain model year 2021-2022 Gladiator, MetroStar, and MetroStar-RT model emergency response chassis cabs equipped with Meritor Series 180 Axle Pinion Shaft.
What is the defect?
It has been reported that some Meritor drive pinion 180 series axles may be fractured in the pinion spline.
If this defect exists, the fracturing of the pinion may hit the brake drop hose which may unintentionally apply the parking brake without detection or brake lights coming on, increasing the risk of a crash. The issue could occur without warning.
What is the manufacturer doing?
A Meritor representative will contact you to schedule the axle pinion inspection and repair as needed. The inspection will need to be performed with a service technician and Meritor representative. The inspection will take approximately 1 hour. If it is determined that the pinion is fractured, Meritor will inform you and Spartan that the Differential Carrier Housing Assembly will need to be replaced. Meritor and Spartan will help locate an authorized service facility if you are unable to complete the replacement of the assembly once it is received. The repair will take approximately five hours to complete. There is no cost to the vehicle owner for the recall remedy.
What should you do?
A Meritor representative will contact you to have the inspection scheduled at a service center nearest to you and completed at no charge.
If you have any questions or concerns, please contact:
Spartan Warranty – P: 800-867-6478
Marion Body Works – Fire & Emergency Warranty – P: 715-754-5261
Chronology :
June 2020 – Pinion crack found on campus in Charlotte during a different PSR.
August – September 2020 – They completed tests to attempt to replicate and could not reproduce the fracture.
Implemented 100% mag particle inspection on all 186R series. Meritor Product Engineering provided a high confidence level that this would be an infancy failure (during the carriers first high load event) due to the fracture signature.
April 2021 – Claim created through standard warranty process for pinion crack.
July 2021 – Pinion failure during delivery to the dealer from the plant. Facilitated warranty claim through Meritor, they provided new gear set.
September 2021 – Houston reached out regarding a pinion crack failure while in service (24 hours in service and under 3,000 miles), was second truck of fleet with similar failure. Pinion broke off and damaged the spring brake air supply line. Metro and Houston insisted an inspection method to validate that the rest of the fleet do not have the same failures. This resulted in Meritor completing an on-site ultrasonic test for the rest of the fleet. Meritor provided corrective action and containment dates, as well as their assessment that this issue is low risk.
October 2021 – Spartan risk assessment completed.
October – November 2021 – Reviewed past precedence. Reached out to all REV Fire businesses to check for any Meritor pinion warranty issues. E-One had one failure in the field in October 2021 but a different axle series affected. Met with Meritor to review the cause again and the potential affected population.
November 10, 2021 – Escalated the issue to REV Group Management.
November 15, 2021 – REV’s senior leadership approved a voluntary recall for this issue.
4 Affected Products
Vehicles
MAKE | MODEL | YEAR |
SPARTAN FIRE | GLADIATOR | 2021-2022 |
SPARTAN FIRE | METROSTAR | 2021-2022 |
7 Associated Documents
Recall Acknowledgement
RCAK-22V019-6831.pdf 645.231KB
Defect Notice 573 Report
RCLRPT-22V019-4080.PDF 215.79KB
Recall 573 Report- 04/18/2022
RCLRPT-22V019-2282.PDF 215.792KB
Recall Quarterly Report #1, 2022-1
RCLQRT-22V019-4755.PDF 239.325KB
Recall Quarterly Report #2, 2022-2
RCLQRT-22V019-8549.PDF 211.229KB
Recall Quarterly Report #3, 2022-3
RCLQRT-22V019-1642.PDF 211.307KB
Owner Notification Letter(Part 577)
RCONL-22V019-4811.pdf 112.171KB
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=22V019&docType=RCL
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SEOCONTENT-START
January 25, 2022 Important Safety Recall Information – Recall Number: 22V-019 Affected Chassis: Dear Valued Customer, This notice is sent to you in accordance with the requirements of the National Traffic and Mortor Vehicle Safety Act. Spartan Fire, LLC has decided that a defect which relates to motor vehicle safety exists in certain model year 2021-2022 Gladiator, MetroStar, and MetroStar-RT model emergency response chassis cabs equipped with Meritor Series 180 Axle Pinion Shaft. What is the defect? It has been reported that some Meritor drive pinion 180 series axles may be fractured in the pinion spline. If this defect exists, the fracturing of the pinion may hit the brake drop hose which may unintentionally apply the parking brake without detection or brake lights coming on, increasing the risk of a crash. The issue could occur without warning. What is the manufacturer doing? A Meritor representative will contact you to schedule the axle pinion inspection and repair as needed. The inspection will need to be performed with a service technician and Meritor representative. The inspection will take approximately 1 hour. If it is determined that the pinion is fractured, Meritor will inform you and Spartan that the Differential Carrier Housing Assembly will need to be replaced. Meritor and Spartan will help locate an authorized service facility if you are unable to complete the replacement of the assembly once it is received. The repair will take approximately five hours to complete. There is no cost to the vehicle owner for the recall remedy. What should you do? A Meritor representative will contact you to have the inspection scheduled at a service center nearest to you and completed at no charge. If you have any questions or concerns, please contact: Spartan Warranty – P: 800-867-6478 Marion Body Works – Fire & Emergency Warranty – P: 715-754-5261 If after having attempted to take advantage of this recall you believe you have not been able to have your vehicle remedied without charge and within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, D.C. 20590 or call the toll-free vehicle safety hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safecar.gov. We apologize for any inconvenience this may cause, your safety is our first concern. Sincerely, Rachel Heineman Quality & Continuous Improvement Manager
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-019 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Marion Body Works Inc. Submission Date : JAN 20, 2022 NHTSA Recall No. : 22V-019 Manufacturer Recall No. : 21V-899 Manufacturer Information : Manufacturer Name : Marion Body Works Inc. Address : 211 West Ramsdell St. Marion WI 54950 Company phone : 715-754-5261 Population : Number of potentially involved : 11 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Spartan Gladiator, MetroStar and MetroStar-RT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The basis for this recall population is vehicle equipped with Meritor drive pinion build in a 180 axle series. Meritor provided an affected rear axle serial number list that was cross-referenced with Spartan Fire’s databases to determine the affected population. Production Dates : FEB 10, 2021 – AUG 05, 2021 VIN Range 1 : Begin : 4S9AU2D98MC560307 End : 4S9AU2E99MC560332 ✔ Not sequential Description of Defect : Description of the Defect : Meritor drive pinion 180 series fractured in the spline. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If this condition exists, the fracture of the pinion may hit the brake drop hose which may unintentionally apply parking brake without detection or brake lights coming on, possibly resulting in a crash. Description of the Cause : There was a variation in the pinion spline tooling geometry of the Meritor process. Identification of Any Warning that can Occur : The issue could occur without warning. Involved Components : Part 573 Safety Recall Report 22V-019 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Rear Axle Carrier Component Description : Pinion Shaft Component Part Number : 180 Series Supplier Identification : Component Manufacturer Name : Meritor Address : 22021 Skyway Church Rd Maxton North Carolina 28364 Country : United States Chronology : June 2020 – Pinion crack found on campus in Charlotte during a different PSR. August – September 2020 – They completed tests to attempt to replicate and could not reproduce the fracture. Implemented 100% mag particle inspection on all 186R series. Meritor Product Engineering provided a high confidence level that this would be an infancy failure (during the carriers first high load event) due to the fracture signature. April 2021 – Claim created through standard warranty process for pinion crack. July 2021 – Pinion failure during delivery to the dealer from the plant. Facilitated warranty claim through Meritor, they provided new gear set. September 2021 – Houston reached out regarding a pinion crack failure while in service (24 hours in service and under 3,000 miles), was second truck of fleet with similar failure. Pinion broke off and damaged the spring brake air supply line. Metro and Houston insisted an inspection method to validate that the rest of the fleet do not have the same failures. This resulted in Meritor completing an on-site ultrasonic test for the rest of the fleet. Meritor provided corrective action and containment dates, as well as their assessment that this issue is low risk. October 2021 – Spartan risk assessment completed. October – November 2021 – Reviewed past precedence. Reached out to all REV Fire businesses to check for any Meritor pinion warranty issues. E-One had one failure in the field in October 2021 but a different axle series affected. Met with Meritor to review the cause again and the potential affected population. November 10, 2021 – Escalated the issue to REV Group Management. November 15, 2021 – REV’s senior leadership approved a voluntary recall for this issue. Part 573 Safety Recall Report 22V-019 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Meritor will conduct an on-site ultrasonic test inspection for the affected population. This will be covered under normal warranty process. Defect units will be replaced at no cost by Meritor How Remedy Component Differs from Recalled Component : NA Identify How/When Recall Condition was Corrected in Production : Meritor has implemented containment in their production facility as of April 20, 2021 and corrective action of tooling implementation as of August 2021. Recall Schedule : Description of Recall Schedule : Marion Body Works to notify dealers and end users by week of February 1, 2022. Planned Dealer Notification Date : FEB 01, 2022 – FEB 04, 2022 Planned Owner Notification Date : FEB 01, 2022 – FEB 04, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-019 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Marion Body Works Inc. Submission Date : APR 18, 2022 NHTSA Recall No. : 22V-019 Manufacturer Recall No. : 21V-899 Manufacturer Information : Manufacturer Name : Marion Body Works Inc. Address : 211 West Ramsdell St. Marion WI 54950 Company phone : 715-754-5261 Population : Number of potentially involved : 22 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Spartan Gladiator, MetroStar and MetroStar-RT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The basis for this recall population is vehicle equipped with Meritor drive pinion build in a 180 axle series. Meritor provided an affected rear axle serial number list that was cross-referenced with Spartan Fire’s databases to determine the affected population. Production Dates : FEB 10, 2021 – AUG 05, 2021 VIN Range 1 : Begin : 4S9AU2D98MC560307 End : 4S9CU2D91MC560562 ✔ Not sequential Description of Defect : Description of the Defect : Meritor drive pinion 180 series fractured in the spline. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If this condition exists, the fracture of the pinion may hit the brake drop hose which may unintentionally apply parking brake without detection or brake lights coming on, possibly resulting in a crash. Description of the Cause : There was a variation in the pinion spline tooling geometry of the Meritor process. Identification of Any Warning that can Occur : The issue could occur without warning. Involved Components : Part 573 Safety Recall Report 22V-019 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Rear Axle Carrier Component Description : Pinion Shaft Component Part Number : 180 Series Supplier Identification : Component Manufacturer Name : Meritor Address : 22021 Skyway Church Rd Maxton North Carolina 28364 Country : United States Chronology : June 2020 – Pinion crack found on campus in Charlotte during a different PSR. August – September 2020 – They completed tests to attempt to replicate and could not reproduce the fracture. Implemented 100% mag particle inspection on all 186R series. Meritor Product Engineering provided a high confidence level that this would be an infancy failure (during the carriers first high load event) due to the fracture signature. April 2021 – Claim created through standard warranty process for pinion crack. July 2021 – Pinion failure during delivery to the dealer from the plant. Facilitated warranty claim through Meritor, they provided new gear set. September 2021 – Houston reached out regarding a pinion crack failure while in service (24 hours in service and under 3,000 miles), was second truck of fleet with similar failure. Pinion broke off and damaged the spring brake air supply line. Metro and Houston insisted an inspection method to validate that the rest of the fleet do not have the same failures. This resulted in Meritor completing an on-site ultrasonic test for the rest of the fleet. Meritor provided corrective action and containment dates, as well as their assessment that this issue is low risk. October 2021 – Spartan risk assessment completed. October – November 2021 – Reviewed past precedence. Reached out to all REV Fire businesses to check for any Meritor pinion warranty issues. E-One had one failure in the field in October 2021 but a different axle series affected. Met with Meritor to review the cause again and the potential affected population. November 10, 2021 – Escalated the issue to REV Group Management. November 15, 2021 – REV’s senior leadership approved a voluntary recall for this issue. Part 573 Safety Recall Report 22V-019 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Meritor will conduct an on-site ultrasonic test inspection for the affected population. This will be covered under normal warranty process. Defect units will be replaced at no cost by Meritor How Remedy Component Differs from Recalled Component : NA Identify How/When Recall Condition was Corrected in Production : Meritor has implemented containment in their production facility as of April 20, 2021 and corrective action of tooling implementation as of August 2021. Recall Schedule : Description of Recall Schedule : Marion Body Works to notify dealers and end users by week of February 1, 2022. Planned Dealer Notification Date : FEB 01, 2022 – FEB 04, 2022 Planned Owner Notification Date : FEB 01, 2022 – FEB 04, 2022 * NR – Not Reported
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