2007 Champion Defender problems

Defect

Champion Bus, Inc. (Champion) is recalling certain model year 2006-2015 Challenger, Defender, Crusader, American, American Coach, American Crusader, Corporal, CTS-FE, CTS-RE, HC American, Platinum Shuttle, and Stacked Rail transit buses manufactured January 1, 2006, to August 25, 2015, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts. The affected lifts are equipped with folding link arms that may have pivot holes that are too big, allowing the bearings to move out of position.

Consequence

If the bearings move out of position, the stowed platform may have excessive movement resulting in failure of the platform mounting. This failure could cause the wheel chair lift platform to fall out of the vehicle when the doors are opened, increasing the risk of injury for the lift operator.

Remedy

Champion will notify owners, and Ricon will inspect the link arms for damage or for displaced bearings. The platform will be inspected for cracks. Any damaged parts will be replaced, free of charge. The recall began on December 21, 2015. Owners may contact Champion customer service at 1-810-724-1753 extension 415, or Ricon customer service at 1-800-322-2884. Champion's number for this recall is 15E-068. Note: These buses and wheelchair lifts were subject to a similar recall in 2014. All vehicles that received that recall remedy are still affected by this recall as well.

Defect

Champion Bus, Inc. (Champion Bus) is recalling certain model year 2006-2014 American Coach, American Crusader, Challenger, Corporal, Crusader, CTS-FE, CTS-RE, Defender, HCAC, HC American, Platinum Shuttle, and Stacked Rail transit buses manufactured January 1, 2006, to July 31, 2014, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation. The platform side plate of the affected wheelchair lifts may crack.

Consequence

If the platform side plates crack, the lift platform can separate from the lift and come to rest against the vehicle's lift door. When the doors are opened, the platform may fall out, increasing the risk of injury to the lift operator.

Remedy

Champion Bus will notify owners to take buses to a Ricon dealer or service center who will install supplemental platform support bumpers. Any platform that has already started cracking will be replaced, free of charge. The recall began in November 2014. Owners may contact Champion Bus customer service at 1-810-724-6474. Owners may contact Ricon customer service at 1-800-322-2884.

Defect

CHAMPION BUS HAS NOTIFIED NHTSA OF A DEFECT IN CERTAIN MODEL YEAR 2007-2010 BUSES FITTED WITH RICON PUBLIC USE LIFTS. THE RESTRAINT BELT ON THESE LIFTS WAS DESIGNED TO PREVENT THE LIFT FROM MOVING, UNLESS THE TONGUE OF THE BELT IS FULLY ENGAGED AND LATCHED IN THE BUCKLE. RICON HAS DISCOVERED, HOWEVER, THAT IT IS POSSIBLE FOR THE OPERATOR TO INSERT THE BELT TONGUE INTO THE BUCKLE WITHOUT FULLY ENGAGING THE LATCHING MECHANISM. IN THIS CASE, THE RESTRAINT BELT WOULD APPEAR TO BE LATCHED, AND THE OPERATOR COULD RUN THE LIFT. IF THE RESTRAINT BELT TONGUE IS NOT FULLY ENGAGED INTO THE RESTRAINT BELT BUCKLE, AND LATCHED, THE LIFT MAY OPERATE WITH AN OCCUPANT ON THE PLATFORM.

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE WITHOUT THE RESTRAINT BELT PROPERLY BUCKLED.

Remedy

CHAMPION BUS IS WORKING WITH RICON AND RICON WILL BE HANDLING THE REMEDY FOR THIS CAMPAIGN. PLEASE SEE RICON'S DEFECT REPORT 09E-060. RICON WILL PROVIDE CUSTOMERS WITH A WARNING DECAL AND A DVD-BASED TRAINING AID. THE SAFETY RECALL BEGAN ON MAY 5, 2010. OWNERS MAY CONTACT RICON CUSTOMER SERVICE AT 800-322-2884, EMAILING AT WWW.DMATA@WABTEC.COM.

Defect

CHAMPION BUS HAS NOTIFIED NHTSA OF A DEFECT IN CERTAIN MODEL YEAR 2006-2010 BUSES EQUIPPED WITH TRANS/AIR AIR CONDITIONING SYSTEMS INSTALLED BETWEEN MAY 2006 AND JUNE 2009. EACH TRANS/AIR SYSTEM COMES WITH AN ELECTRICAL KIT WHICH CONTAINS A RELAY BOARD AND EC PC BOARD WHICH IF IMPROPERLY INSTALLED COULD OVERHEAT.

Consequence

AN ELECTRICAL FAILURE IN THE RELAY BOARD, CAN CAUSE OVERHEATING AND POSE A SERIOUS FIRE HAZARD.

Remedy

TRANS AIR WILL NOTIFY THE OWNERS AND THE BUSES WILL BE REPAIRED FREE OF CHARGE. PLEASE ALSO SEE TRANS/AIR DEFECT REPORT 09E-042. THE SAFETY RECALL BEGAN ON MAY 19, 2010. OWNERS MAY CONTACT TRANS/AIR WARRANTY AND SERVICE DEPARTMENT AT 1-800-673- 2446.

Defect

CHAMPION BUS IS RECALLING CERTAIN MODEL YEAR 2003 THROUGH 2010 TRANSIT BUSES MANUFACTURED BETWEEN JANUARY 2003 AND AUGUST 2009 EQUIPPED WITH LUMINATOR HORIZON LED SIDE DESTINATION SIGNS. THE CONNECTOR BOARD CAN CORRODE DUE TO AN ACCUMULATION OF MOISTURE UNDER THE CONNECTOR.

Consequence

A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.

Remedy

CHAMPION BUS WILL NOTIFY OWNERS AND LUMINATOR WILL REPAIR THE BUSES FREE OF CHARGE. PLEASE SEE LUMINATOR'S DEFECT REPORT 09E-054. THE SAFETY RECALL BEGAN ON DECEMBER 11, 2009. OWNERS MAY CONTACT LUMINATOR AT 1-972-516-3033 OR CHAMPION BUS AT 1-800-331-5761.

Defect

CHAMPION BUS IS RECALLING 36 MODEL YEAR 2004, 2005, AND 2007 DEFENDER AND MODEL YEAR 2005-2006 M1000 BUSES BUILT BETWEEN APRIL 12, 2004 AND SEPTEMBER 18, 2006. CERTAIN HYDRAULIC BRAKE LINES MAY CONTACT THE TRANSMISSION DIPSTICK TUBE AS THE ENGINE ROCKS.

Consequence

CONTINUED CONTACT BETWEEN THE BRAKE LINE AND THE DIPSTICK TUBE COULD CAUSE A BRAKE FLUID LEAK AND REDUCE BRAKE PERFORMANCE, POTENTIALLY RESULTING IN A CRASH WITHOUT WARNING.

Remedy

DAIMLER TRUCKS IS HANDLING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. PLEASE SEE 09V-114. DAIMLER TRUCKS WILL CORRECT THE CHASSIS IF FOUND TO BE DEFECTIVE. THIS SERVICE WILL BE PERFORMED FOR YOU FREE OF CHARGE. OWNERS MAY CONTACT DAIMLER TRUCKS AT 1-800-547-0712.

Defect

CHAMPION BUS IS RECALLING 503 MY 2005-2007 CHALLENGER, CRUSADER, DEFENDER, MY 2005-2006 CORPORAL, MY 2006 CTS-RE, AND MY 2007 CTS-FE AND IC DEFENDER TRANSIT BUSES EQUIPPED WITH A RICON PLATFORM STYLE WHEELCHAIR LIFT. THIS LIFT FAILS TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEMS FOR MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Consequence

A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy

CHAMPION BUS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFT FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR CHAMPION BUS AT 1-800-331-5761.

Defect

CHAMPION IS RECALLING 68 MY 2007-2009 TRANSIT BUSES. THE FASTENERS THAT ARE USED TO HOLD ELECTRICAL CONNECTORS IN PLACE ON THE ROOF MOUNTED AIR CONDITIONER CONTROL PANEL MAY NOT BE TIGHTENED DOWN TO THE PROPER TORQUE AND/OR THERE MAY BE A POSSIBLE FRAYED WIRE AT THE CONNECTION POINT.

Consequence

IF THESE CONNECTIONS ARE LOOSE, IT COULD RESULT IN OVERHEATING AND CAUSE A FIRE.

Remedy

DEALERS WILL INSPECT THE FASTENERS ON THE ELECTRICAL CONTROL BOARD AND TIGHTEN THEM TO THE PROPER TORQUE VALUE IF THEY ARE FOUND TO BE LOOSE. THE RECALL BEGAN ON JULY 1, 2008. OWNERS MAY CONTACT CHAMPION BUS AT 1-810-724-1735.

Defect

CHAMPION BUS IS RECALLING 31 MY 2007-2008 DEFENDER, CHALLENGER AND MY 2008 CRUSADER BUSES BUILT ON GENERAL MOTORS 560 CHASSIS AND EQUIPPED WITH INTERMOTIVE GATEWAY 401 MODULE INTERLOCK HARNESS. THESE BUSES HAVE BEEN FOUND TO EXHIBIT EXTREME VOLTAGE SPIKES DURING ENGINE CRANKING. THESE EXTREME SPIKES CAN DAMAGE THE DIODE IN THE HARNESS NEAR THE SHIFT LOCK SOLENOID CONNECTOR. IF THE DIODE FAILS IN THE SHORTED CONDITION, THE GATEWAY 401 MODULE CAN BE DAMAGED.

Consequence

IF THIS OCCURS, THE SHIFT LOCK SOLENOID MAY NOT ENGAGE. IF THIS LOCK DOES NOT ENGAGE, THE VEHICLE WILL HAVE THE ABILITY TO MOVE WHILE THE WHEELCHAIR LIFT IS DEPLOYED WHICH MAY RESULT IN PERSONAL INJURY.

Remedy

INTERMOTIVE IS HANDLING THE REMEDY FOR THIS CAMPAIGN (PLEASE SEE 08E004). INTERMOTIVE WILL REPLACE THE DEFECTIVE HARNESS FREE OF CHARGE. OWNERS MAY CONTACT INTERMOTIVE AT 1-800-969-6080 OR CHAMPION BUS AT 1-810-724-6474.

Defect

CHAMPION BUS IS RECALLING 503 MY 2005-2008 DEFENDER, CHALLENGER, CTS-RE, CTS-FE AND CRUSADER BUSES EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

CHAMPION BUS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR CHAMPION BUS AT 1-937-596-6849.