2023 Gillig Low Floor problems

Defect

Gillig, LLC (Gillig) is recalling certain 2023-2024 Low Floor transit buses equipped with Michelin X InCity Grip D rear tires. The rear Gross Axle Weight Rating (GAWR) on the federal placard may exceed the tire load rating. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 120, "Wheels and Rims - Other Than Passenger Cars."

Consequence

Referencing an incorrect GAWR can lead to unintentionally overloading the rear tires, increasing the risk of a crash.

Remedy

Gillig will replace the federal placard, free of charge. Owner notification letters are expected to be mailed April 24, 2026. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023-2026 Low Floor transit buses. The high voltage cable, connecting the inverter to the drive unit, contains a splice connection that reduces the amp capacity rating.

Consequence

Reduced capacity may cause the cable to overheat, increasing the risk of a fire.

Remedy

Gillig will reprogram the software as an interim repair. For the final remedy, Gillig will replace the high voltage cable. Both repairs will be provided free of charge. Interim owner notification letters explaining the safety risk were mailed April 14, 2026. Another notice will be sent once the final remedy becomes available. Owners may contact Gillig's customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2021-2026 Low Floor transit buses. The air compressor intake pipe may contact and damage the fuel line.

Consequence

A damaged fuel line may leak, increasing the risk of a fire.

Remedy

Gillig will inspect, replace, and reorient the intake pipe as necessary, free of charge. Owner notification letters were mailed April 24, 2026. Owners may contact Gillig's customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023-2024 Low Floor transit buses. The high voltage batteries may have loose hardware that can fall inside the battery pack and create a short circuit.

Consequence

A short circuit increases the risk of a fire. In addition, the battery contactors may open suddenly and cause a loss of drive power, increasing the risk of a crash.

Remedy

Gillig will install new battery fasteners as necessary, free of charge. Owner notification letters were mailed April 28, 2025. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2019-2024 Low Floor transit buses. The rivet-nut fasteners that secure the TFT flat panel display monitor to the bus ceiling may fail, causing the monitor to detach and fall.

Consequence

A monitor that detaches and falls from the ceiling increases the risk of injury.

Remedy

Gillig will replace the rivet-nut fasteners, free of charge. Owner notification letters were mailed March 18, 2025. Owners may contact Gillig customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2021-2024 Low Floor style transit buses. The fire suppression relay cable may be damaged, chafing against the mounting bolt, and fail.

Consequence

Failure of the fire suppression system can increase the risk of injury during a fire.

Remedy

Dealers will replace the relay cable, free of charge. Owner notification letters were mailed December 31, 2024. Owners may contact GILLIG customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023-2024 Low Floor style transit buses. The high voltage electric air compressor may not be connected to the High Voltage Interlock Loop (HVIL). Therefore, the HVIL cannot detect a loose or disconnected compressor power cable.

Consequence

Failure to alert the operator to a power cable issue can increase the risk of injury by electrical shock.

Remedy

Dealers will install an additional electrical harness, extending the HVIL loop to the air compressor, free of charge. Owner notification letters were mailed February 12, 2025. Owners may contact GILLIG customer service at 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023 Low Floor diesel-hybrid transit buses. During vehicle operations in full electric vehicle (EV) mode, the odometer will not display accumulated mileage. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 101, "Controls and Displays."

Consequence

A missing odometer reading could lead to an unintended delay in critical safety-related maintenance, potentially impairing the safe operation of the vehicle and increasing the risk of a crash.

Remedy

Gillig will install a new speedometer gauge, free of charge. Owner notification letters were mailed December 20, 2024. Owners may contact Gillig customer service at 1-800-735-1500 or 1-510-264-5073.

Defect

Gillig, LLC (Gillig) is recalling certain 2023-2024 Low Floor transit buses. The steering spline shaft fasteners may have been improperly tightened, allowing the steering spline shaft to loosen.

Consequence

A loose steering shaft can cause a complete loss of steering control, increasing the risk of a crash.

Remedy

Gillig will tighten the fasteners, free of charge. Owner notification letters were mailed August 13, 2024. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023 Low Floor buses equipped with Cummins L9 diesel engines with part number D563027BX03. Insufficient crimping may allow the remote fuel filter hoses to disconnect and leak, decreasing fuel supply to the engine.

Consequence

A fuel leak in the presence of an ignition source increases the risk of a fire. Additionally, a lack of fuel can cause an engine stall, increasing the risk of a crash.

Remedy

Cummins will replace the remote fuel filter hoses. Owner notification letters were mailed June 21, 2024. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2021-2023 Low Floor vehicles. The rearview mirror electric adjustment system may have been manufactured with an incorrect fuse.

Consequence

An incorrect fuse may overheat and increase the risk of a fire.

Remedy

Gillig will replace the protection fuse of the mirror control switch, free of charge. Owner notification letters were mailed January 15, 2024. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2023 Low Floor vehicles. An inadequate amount of lubricant in the rear axle hubs may cause failure of the rear drive axles.

Consequence

Rear drive axle failure can result in a loss of vehicle control and increase the risk of a crash or injury.

Remedy

Gillig will inspect for correct rear axle hub lubricant levels and add lubricant and gear oil as necessary, free of charge. Owner notification letters were mailed January 12, 2023. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2019-2023 Low Floor transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.

Consequence

A sudden loss of drive power can increase the risk of a crash. Additionally, a disabled bus may require an evacuation procedure in an uncontrolled traffic situation, increasing the risk of injury to passengers.

Remedy

Gillig will work with the equipment manufacturer, Allison Transmission Inc., to inspect and tighten the transmission yoke bolts, as necessary, free of charge. Owner notification letters were mailed December 11, 2023. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2022-2023 Low Floor transit buses. The driveshaft fasteners may have been improperly tightened after service repairs, allowing the driveshaft to detach.

Consequence

A detached driveshaft can cause a loss of vehicle control, increasing the risk of a crash.

Remedy

Gillig will replace the driveshaft straps and fasteners, free of charge. Owner notification letters were mailed October 9, 2023. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect

Gillig, LLC (Gillig) is recalling certain 2022-2023 Low Floor transit and shuttle buses. Incompatible steering system draglink parts may have been installed during the vehicle assembly process, potentially resulting in long-term damage of the steering system.

Consequence

A damaged steering system can result in a loss of vehicle handling and control, increasing the risk of a crash.

Remedy

Gillig will inspect and, when necessary, replace and tighten the draglink rod, free of charge. Owner notification letters were mailed March 29, 2023. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.