2014 Gillig Low Floor problems

Defect

Gillig, LLC (Gillig) is recalling certain 2014-2021 Low Floor transit buses. The rear-mounted ultracapacitors may allow the engine to be started when the master battery disconnect switch is in the "OFF" position.

Consequence

The engine may be started unexpectedly, increasing the risk of injury to anyone nearby the engine compartment during maintenance operations.

Remedy

Dealers will update the software for the buses equipped with the Vanner Ultracapacitor system, and conduct a hard rewire for the buses equipped with the KBI system, free of charge. Owner notification letters were mailed on June 22, 2022. Owners may contact Gillig's customer service at 1-510-264-5073 for 1-800-735-1500.

Defect

Gillig, LLC. (Gillig) is recalling certain 2013-2020 hybrid and all-electric Low Floor buses equipped with a steering system that uses a high-voltage electric motor and hydraulic pump assembly to provide power steering assist. The shaft coupling between the motor and pump may fail and cause a loss of hydraulic power steering assist.

Consequence

A loss of power steering assist may increase the risk of crash.

Remedy

Gillig will notify owners, and dealers will replace the motor-pump assemblies, free of charge. The recall began August 13, 2020. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2012-2020 Low Floor buses. The circuit breaker ratings on the DEF Line Heater circuit and the Aftertreatment-Ignition circuit may be higher than the rating for the wire and connector.

Consequence

With the improper circuit breaker rating, an electrical short in either of these circuits may increase the risk of a fire.

Remedy

Gillig will notify owners, and dealers will replace the circuit breakers, free of charge. The recall began April 24, 2020. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2014-2019 Low Floor buses. Uncovered electrical terminals in the headlight power circuit may short circuit to ground, causing a loss of headlights.

Consequence

A loss of headlights can reduce the driver's ability to see, increasing the risk of a crash.

Remedy

Gillig has notified owners, and dealers will install new back covers on the headlight buckets, free of charge. The recall began April 1, 2019. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2013-2018 Gillig Low Floor transit buses equipped with disk brakes. The spring cage bolts on the air brakes may not be sufficiently tightened, reducing the effectiveness of the parking brake.

Consequence

Loose cage bolts may result in the bus rolling away when in the park position or a loss of braking ability if the service brake air pressure is lost while moving. Either condition may increase the risk of a crash.

Remedy

Gillig will notify owners, and dealers will tighten the spring cage bolts, free of charge. The recall began December 10, 2018. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2012-2018 Gillig Low Floor vehicles. The front and rear turn signals on these vehicles may flash at different rates, potentially confusing other drivers of the vehicle's intention. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence

The mismatched flashing may confuse other drivers, increasing the risk of a crash.

Remedy

Gillig will notify the owner of the buses, and dealers will reprogram the turn signals with new software, free of charge. The recall began August 30, 2018. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2001-2018 Gillig Low Floor transit buses. The turn signals may flash slowly, reducing their visibility to other drivers. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence

The reduced visibility of the turn signals can increase the risk of a crash.

Remedy

Gillig will notify owners, and dealers will update the software that controls the turn flash rate, free of charge. The recall began on August 2, 2018. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain 2013-2016 Hybrid and all Electric Low Floor buses with electro-hydraulic power steering assist. The coupler between the high-voltage electric motor and hydraulic steering pump shafts may fail, resulting in a loss of power steering assist.

Consequence

A loss of power steering assist will cause the need for increased steering effort, increasing the risk of a crash.

Remedy

Gillig will notify owners, and dealers will replace the steering motor-pump assemblies, free of charge. The recall began on October 24, 2017. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 1997-2017 Low Floor transit buses. The front turn signals installed on standard profile (non-BRT) buses may not be sufficiently visible to other drivers or pedestrians. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence

The reduced visibility of the turn signals may increase the risk of a crash.

Remedy

Gillig will notify owners, and dealers will install turn signals that have increased visibility. The recall began June 7, 2019. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2014-2016 Gillig 29-foot Low Floor transit buses manufactured November 20, 2014, to February 11, 2016. These buses, equipped with disc brakes, have rear brake hoses that can rub chassis components and fray.

Consequence

A frayed hose may leak air, causing the rear brake(s) to lock up unexpectedly, or fail to operate when the brakes are applied. Either scenario increases the risk of a crash.

Remedy

Gillig will provide fleets new rear brake hoses, fittings, clamps, and hardware along with instructions on how to reorient the hoses using the new fittings, and reimburse them for their labor, free of charge. The recall began on September 29, 2016. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2012-2016 Lowfloor diesel-electric hybrid vehicles manufactured March 6, 2012, to June 7, 2016. The affected vehicles are equipped with stop lamp activation that may inadvertently flash the rear brake lights. As such, these vehicles do not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 108, "Lamps, Reflective Devices, and Assoc. Equipment."

Consequence

Flashing brake lights may cause confusion to other drivers, increasing the risk of a crash.

Remedy

Gillig will notify owners, and dealers will install a new software update, free of charge. The recall began on July 2016. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2010-2015 Low Floor transit buses manufactured April 1, 2010 to October 30, 2015, equipped with Recaro Ergo-M Commercial Bus Driver Seats. The affected seats have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.

Consequence

If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.

Remedy

Gillig will notify the owners, and dealers will inspect the seats to determine if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on March 1, 2016. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2014-2015 Low Floor vehicles manufactured November 20, 2014, to June 2, 2015. The affected vehicles may be equipped with front brake chambers with an incorrect drain hole orientation. This can allow water to build up within the brake chamber, causing corrosion, deterioration, and reduce braking ability.

Consequence

Corrosion, part deterioration, or frozen water in the brake chamber may reduce braking ability, increasing the risk of a crash.

Remedy

Gillig will notify owners and the brake chambers will be replaced free of charge. The recall began on March 1, 2016. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2010-2015 Low Floor transit buses manufactured April 13, 2010, to June 12, 2015. Due to the routing of the grid heater electrical power cable, the cable may chafe against a fuel injector hard line.

Consequence

If the electrical power cable rubs against the injector fuel line, the cable may short circuit or the fuel line may leak fuel. Either possibility increases the risk of a fire.

Remedy

Gillig will notify owners, and dealers will inspect the grid heater power cable/hard injector fuel line for wear, and will properly route and support the grid heater power cable, free of charge. The recall began on July 17, 2015. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2014-2015 Low Floor vehicles manufactured September 1, 2014, to April 30, 2015. The affected vehicles may have a taillight bracket that is inadequately bonded to the bus body.

Consequence

If the bracket is inadequately bonded, it may detach from the body, preventing the stop and turn lights from being visible to following vehicles, increasing the risk of a crash.

Remedy

Gillig has notified owners. Gillig will inspect the taillight brackets to verify that they are properly bonded to the body. Brackets that are not properly bonded will be removed and properly bonded to the vehicle, free of charge. The recall began on June 12, 2015. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2010-2015 Lowfloor vehicles manufactured August 26, 2010, to April 30, 2015. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.

Consequence

If engine oil comes into contact with a hot surface, there is an increased risk of a fire.

Remedy

Gillig will notify owners, and dealers will secure the ends of the 90-degree elbow. In addition, the electronic control module (ECM) will be reprogrammed with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 2, 2015. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2013-2015 Low Floor transit buses manufactured July 8, 2013, to February 7, 2015 and equipped with disc brakes. The front left and right brake air hoses that connect to the brake chamber may touch and rub against the air bag suspension towers.

Consequence

If the front brake hoses rub the air bag suspension tower, a hole may develop and the resulting air leak may reduce the brake air pressure, lengthening the distance needed to stop the transit bus and increasing the risk of a crash.

Remedy

Gillig has notified owners, and dealers will replace the brake hoses with shorter ones that will not contact the suspension tower, free of charge. The recall began on April 28, 2015. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2014 Lowfloor transit buses manufactured January 2, 2014, to March 6, 2014. In the affected vehicles, the air brake system supply lines from the primary and secondary air tanks to the brake valves may have been crossed at the bulkhead during assembly. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 121, "Air Brake Systems."

Consequence

If the primary and secondary air brake supply lines from the tanks to the brake valve are crossed and the vehicle loses pressure in the primary tank, the vehicle service brake system performance may be reduced. In the case of a total loss of primary tank air pressure, the service brake system will not function. If the service brake system does not function or performance is reduced, an application of the brake pedal by the vehicle operator may not slow or stop the vehicle as expected, increasing the risk of a crash.

Remedy

Gillig will notify owners, and dealers will correct the installation of the primary and secondary brake supply lines, free of charge. The recall began on October 17, 2014. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2014 Low Floor transit buses manufactured from May 23, 2014, through August 1, 2014. The Cummins ISB or ISL engines in these vehicles may have been equipped with Fleetguard UFF-XT fuel filters, part number FF63009, whose filter shell may separate from the fuel filter nut plate causing the engine to stall without warning.

Consequence

If the engine stalls unexpectedly there is an increased risk of a crash.

Remedy

Cummins will notify owners on behalf of Gillig, and Cummins service centers will replace the fuel filter, free of charge. The recall began on September 16, 2014. Owners may contact Gillig at 1-510-785-1500 or Cummins customer service at 1-812-377-3713.

Defect

Gillig, LLC (Gillig) is recalling certain model year 2013-2014 Low Floor transit buses manufactured July 25, 2013, to June 17, 2014. The affected vehicles may have been produced without a quick release valve for the rear brakes on buses built with rear disc brakes. As such, these vehicles fail to comply with Federal Motor Vehicle Safety Standard No. 121, "Air Brake Systems."

Consequence

If the bus's anti-lock brake system was non-functioning and the bus experienced a significant braking event that when combined with the road conditions may lock the rear brakes, then a delay in brake release timing could result in a lock up of the rear wheels, increasing the risk of crash.

Remedy

Gillig will notify owners, and dealers will install a quick release valve, free of charge. The recall began on September 15, 2014. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain model year 2007-2014 Lowfloor transit buses manufactured September 26, 2007, through January 24, 2014. In the affected vehicles, the engine oil sampling hose may leak oil due to being routed too closely to hot engine exhaust components.

Consequence

If the sampling hose leaks oil in the presence of hot engine engine exhaust components, there is an increased risk of fire.

Remedy

Gillig will notify owners, and dealers will inspect the oil sampling hose. If the hose is routed too closely, the hose will be removed, replaced and rerouted to provide appropriate clearance of the hot components. The recall is expected to begin in early August 2014. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC (Gillig) is recalling certain model year 2012-2014 Lowfloor transit buses manufactured October 15, 2012, through March 26, 2014, and equipped with electrical harnesses with overmolded J1939 connectors and non-insulated drain wires. The harnesses do not have heat shrink tubing on the drain wire and the overmold may not have sufficient resistance to water or corrosive chemical entry to the connectors.

Consequence

If the terminals corrode, there may be an intermittent electrical connection and possibly cause disruption or loss of the J1939 communication, resulting in interruptions of the engine, transmission, ABS and body controllers, increasing the risk of a crash.

Remedy

Gillig will notify owners, and dealers will replace the overmold connector, and install heat shrink tubing on the connector/cable junction, free of charge. The recall began in June 2014. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig LLC is recalling certain model year 2010-2014 Lowfloor transit buses manufactured August 26, 2010, through February 14, 2014, and equipped with certain Cummins Westport model ISL G engines. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.

Consequence

The improper operation of the sensor could induce elevated exhaust temperatures or flames from the exhaust pipe, increasing the risk of a vehicle fire.

Remedy

Cummins Inc. and Cummins Wesport Inc. will notify owners, and dealers will upload a new ECM calibration, free of charge. The recall began on March 20, 2014. Owners may contact Gillig LLC at 1-510-785-1500 or Cummins Inc. at 1-800-343-7357.