After a preliminary review of consumer complaints and other information related to alleged defects, NHTSA obtains information from the manufacturer(including data on complaints, crashes, injuries, warranty claims, modifications, and part sales) and determines whether further analysis is warranted. If warranted, the investigator will conduct a more detailed and complete analysis of the character and scope of the alleged defect.
NHTSA Action Number: PE11007
Date Opened: 2011-03-29
Date Closed: 2011-09-23
Manufacturer’s Name: FREIGHTLINER
LLC
Component Description: PARKING BRAKE:DRIVELINE:AIR:CHAMBER
Summary Description: Haldex Brake Chamber Spring Failures
Summary
ODI opened this preliminary evaluation based on a fleet report that it had experienced multiple wheel-end fires.The fleet believed this was due to the power spring fracturing and subsequently puncturing the diaphragm resulting in an air loss causing the brakes to drag.A vehicle driver suffered smoke inhalation during one of the fires suspected to have been caused by the alleged defect.Another injury was sustained by a mechanic when he attempted to remove the brake chamber with a broken power spring.The brake chamber sprung from its mounting bracket and struck the mechanic in the face, causing multiple lacerations.Brake chambers have a limited life span and are subject to wear out.However, the failures identified by the fleet are much earlier than expected and may not exhibit discernible failure symptoms.ODI initiated testing at the Vehicle Research and Test Center (VRTC) to determine the cause of the spring failure and to better understand any warning signs that may be present.VRTC's testing is ongoing as is Haldex's inspection of failed chambers returned from the fleet.This PE has been upgraded to an Engineering Analysis (EA11-011) to further evaluate the cause of the fires and assess the scope, frequency, and safety consequences of the alleged defect.
NHTSA Action Number: PE11008
Date Opened: 2011-03-29
Date Closed: 2012-01-30
Manufacturer’s Name: Caterpillar, Inc.
Component Description: ENGINE AND ENGINE COOLING:ENGINE:DIESEL
Recall Campaign: 11E051
Summary Description: Caterpillar C7 Hose Leak
Summary
The Office of Defects Investigation (ODI) received 1 fleet complaint (involving 8 incidents on 6 vehicles) alleging that the Clean Gas Induction (CGI) coolant lines on affected vehicles had developed leaks resulting in a vehicle stall.Caterpillar conducted system testing and determined that coolant in the subject engines may become increasingly acidic over time, which may result in damage to the inner walls of the coolant hoses.In at least four (4) cases this has resulted in stranded school buses due to coolant loss.Caterpillar (CAT) submitted a recall notice on December 2, 2011.CAT's announcement of a safety recall on this matter addresses ODI's concerns.Coolant will be checked and changed more frequently to prevent in-field pH degradation and coolant hoses damaged from this issue will be replaced under warranty. The subject vehicles have been recalled, therefore this investigation is closed.The ODI report cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) number: 10446420
NHTSA Action Number: PE11006
Date Opened: 2011-02-28
Date Closed: 2011-08-05
Manufacturer’s Name: Pierce Manufacturing
Component Description: FUEL SYSTEM, DIESEL
Recall Campaign: 11V384
Summary Description: Fuel Tank Straps Fail due to Corrosion
Summary
On February 28th 2011 the Office of Defects Investigations (ODI) opened a Preliminary Evaluation (PE11-006) on certain Pierce fire trucks for fuel tank straps that fail due to corrosion; allowing the fuel the tank to drop from the vehicle.Pierce determined that some fire trucks may be exposed to winter road de-icing chemicals. Over a period of time the fuel tank straps may corrode. This corrosion will weaken the fuel tank straps causing the strap(s) to fail/fracture and allow the fuel tank to separate from the vehicle. If the tank were to drop on the roadway while the vehicle was in motion, the vehicle may stall and lose power. In addition, other surrounding vehicles, trying to avoid the fire truck and or the loose fuel tank may lose control. The danger of a loose fuel tank, spilling its fuelonto the road is also a concern.If either or both of these conditions were to take place, a crash could occur.Pierce's safety recall (11V-385) is an inspect-and-repair campaign.To reduce the risk of failed tank straps, Pierce is making available to all consumers stainless fuel tank straps upon an inspection of the existing ones.If corrosion is found, Pierce will replace the old corrosion prone fuel straps with new stainless straps.The vehicles included in this safety recall are: certain Arrow XT, Dash, Custom Contender, Lance, Enforcer, Pierce Arrow, Quantum, Saber & Commercial fire apparatus models manufactured between January 2, 1995 and January 21, 2008.This Preliminary Evaluation is closed.See NHTSA recall 11V-385.
NHTSA Action Number: EQ11002
Date Opened: 2011-02-17
Date Closed: 2012-05-25
Manufacturer’s Name: Carrier Corporation
Component Description: EQUIPMENT:APPLIANCE:AIR CONDITIONER
Recall Campaign: 11E003
Summary Description: Carrier A/C Evaporator Fires
Summary
On January 25, 2011, Carrier Corporation (Carrier) notified the NHTSA that it had decided certain GenV EM-1 evaporator assemblies, installed into school buses and shuttle buses, contain a safety related defect.Carrier stated that certain EM-1 evaporators, manufactured between January 2006 and December 2010, contain a Delphi Pack-Con III fuse holder in an Allied Motion motor assembly.Over time, the Delphi fuse holder contacts may relax and possibly produce arcing.If sufficient arcing occurs, the fuse holder may melt, and may be accompanied by flame, smoke and potential fire.This issue was assigned recall number 11E-003.On February 2, 2011, RMD contacted Delphi Corporation (Delphi) via e-mail to learn if it intended to file a Part 573 Report for the Pack-Con III fuse holders that Carrier deemed defective in its Part 573 filing.On February 17, 2011, Delphi responded via e-mail that this particular fuse holder had been in production since 1976 without any field issues reported to Delphi.Delphi stated that it, ...believes the Pack-Con III fuse holder is not defective and that the Pack-Con III fuse holder was misapplied by Carrier.On March 17, 2011, RMD issued an information request (IR) letter to Delphi to formally request a list of purchasers that received these fuse holders.On March 25, 2011 Delphi responded by supplying a list of purchasers to NHTSA's Office of the Chief Counsel under a request for confidentiality.Given the information supplied in Delphi's earlier February 17, 2011 response, RMD chose not to contact the purchasers of these fuse holders during this EQ as no other vehicle or equipment manufacturers have filed similar safety defect decisions with the NHTSA at this time.RMD may, however, contact these fuse holder purchasers in the future should any other safety defect decisions regarding this equipment be filed with the NHTSA.On October 6, 2011, RMD mailed IR letters to 10 purchasers identified in Carrier?s Part 573 filing in order to learn if any vehicles were manufactured with these EM-1 evaporators.Six manufacturers responded by filing Part 573 Reports for vehicles they manufactured and also conducted safety recalls.Three manufacturers, Sonny Merryman Inc., Colonial Equipment Company, and Rivers Bus Sales responded that their evaporators were only installed into used vehicles or retail sold, neither requiring the companies to conduct safety recalls.Pro Air, LLC (Pro Air) responded that it distributed its more than 5,400 units to companies that might manufacture new motor vehicles.After multiple requests, RMD received Pro Air?s purchaser list on November 29, 2011.On December 14, 2011, RMD mailed IR letters to 5 purchasers identified by Pro Air.Three companies responded by filing Part 573 Reports and conducting safety recalls. Two companies, TMC Group and Herr Display Vans, did not respond to RMD?s IR letter or follow-up e-mails requests.These companies will be referred to NHTSA?s Office of the Chief Counsel for further possible enforcement action.In total, 9 manufacturers filed the following Part 573 Reports as a result of this EQ:11V-502 - Collins Bus Corp. 11V-540 ? Molly Corporation 11V-559 ? Double K, Inc. 11V-571 ? Starcraft Bus 11V-581 ? Kingmor Supply, Inc. 12V-003 ? Elkhart Coach 12V-011 ? Forest River, Glaval Bus Div. 12V-044 ? Turtle Top 12V-179 ? Nesco BusThis Equipment Query is closed.
NHTSA Action Number: PE11005
Date Opened: 2011-02-15
Date Closed: 2011-07-20
Manufacturer’s Name: Toyota Motor Corporation
Component Description: HYBRID PROPULSION SYSTEM: INVERTER
Recall Campaign: 11V342
Summary Description: Hybrid inverter failure - vehicle stall
Summary
In a June 29, 2011 letter to NHTSA, Toyota submitted a Defect Information Report regarding a safety recall of certain Toyota Highlander Hybrid and Lexus RX400h vehicles to address a defect condition with the hybrid inverter assembly (NHTSA Recall No. 11V-342).Toyota's letter identified a defect related to inadequately soldered transistors on the Intelligent Power Module (IPM) of some of the subject vehicles that could result in sudden loss of power while driving.Toyota's remedy procedure instructs dealers to inspect the hybrid inverter production number to determine if the inverter contains suspect transistors.If so, the dealer will replace the IPM.The recall covers approximately 45,528 model year (MY) 2006 and 2007 Toyota Highlander Hybrid vehicles manufactured from February 16, 2005 through August 29, 2006 and approximately 36,745 MY 2006 and 2007 Lexus RX400h vehicles manufactured from February 23, 2005 through August 30, 2006.This Preliminary Evaluation is closed.
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