2011 Gillig LOW FLOOR: complaints, problems and recalls

Reported: 2011-08-10 (August 10, 2011)

GILLIG IS RECALLING CERTAIN MODEL YEAR 2010-2011 LOWFLOOR BUSES EQUIPPED WITH CUMMINS ENGINES. THE V-BAND CLAMP ASSEMBLY USED TO CONNECT THE INLET AND OUTLET CONE SECTIONS TO THE DIESEL OXIDATION CATALYST (DOC) DIESEL PARTICULATE FILTER (DPF) INCLUDE A T-BOLT WHICH CAN FRACTURE AND FAIL WHEN SUBJECTED TO STRESS OR LOAD. A FRACTURE OR FAILURE OF THE T-BOLT MAY CAUSE THE CLAMP TO LOOSEN AND THE INLET OR OUTLET SECTIONS ATTACHED TO THE DOC/DPF HOUSING TO DISCONNECT.

Consequence: IF THE INLET OR OUTLET SECTIONS DISCONNECT, HOT EXHAUST GASES CAN VENT PRIOR TO EXITING THE TAILPIPE, CREATING THE RISK OF COMBUSTION AND A FIRE. IF BOTH CLAMPS FAIL, THERE IS A RISK IN SOME APPLICATIONS THAT THE DOC/DPF HOUSING MAY DETACH COMPLETELY, CREATING A ROAD HAZARD.

Remedy: GILLIG IS WORKING WITH CUMMINS TO IDENTIFY OWNERS. CUMMINS IS HANDLING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN PLEASE SEE NHTSA RECALL 11E-031. OWNERS MAY CONTACT CUMMINS AT 1-812-377-5000.

Reported: 2011-08-25 (August 25, 2011)

GILLIG IS RECALLING CERTAIN MODEL YEAR 2011 LOW FLOOR BUSES MANUFACTURED FROM JUNE 13, 2011, THROUGH AUGUST 12, 2011, EQUIPPED WITH TRW TC34023 STEERING COLUMNS WITH DATE CODES STARTING 157 1 11 AND ENDING 228 1 11. THE TOOTH PROFILE AND SPACING OF THE TILT LOCK TEETH ON THE SUPPORT BRACKET MAY BE INCORRECT, PREVENTING THE TILT LOCK BAR FROM FULLY ENGAGING. THIS MAY ALLOW THE STEERING COLUMN TO SLIP FROM THE DRIVER- SET TILT LOCATION AND MOVE UPWARD UNTIL IT LOCKS IN ANOTHER TILT POSITION.

Consequence: THIS UNINTENDED MOVEMENT OF THE STEERING COLUMN MAY INTERFERE WITH THE DRIVERS CONTROL OF THE VEHICLE AND INCREASE RISK OF A CRASH.

Remedy: GILLIG WILL NOTIFY OWNERS AND GILLIG WILL REPLACE THE STEERING COLUMN FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 16, 2011. OWNERS MAY CONTACT GILLIG FIELD SERVICE AT 1-800-735-1500.

Reported: 2011-12-08 (December 8, 2011)

GILLIG IS RECALLING CERTAIN MODEL YEAR 2011 LOW FLOOR BUSES MANUFACTURED FROM AUGUST 1, 2011, THROUGH OCTOBER 21, 2011, EQUIPPED WITH PARKER HYDRAULIC PUMPS. SOME HYDRAULIC STEERING PUMPS DO NOT DELIVER ENOUGH FLUID OR PRESSURE TO THE STEERING GEAR, MAKING THE BUSES DIFFICULT TO STEER AT LOW SPEEDS.

Consequence: AN UNEXPECTED CHANGE IN THE EFFORT REQUIRED BY THE DRIVER TO TURN THE STEERING WHEEL MAY AFFECT THE DRIVERS’ CONTROL OF THE VEHICLE, INCREASING THE RISK OF A CRASH.

Remedy: GILLIG WILL NOTIFY OWNERS, AND IN CONJUNCTION WITH PARKER TECHNICIANS PARKER WILL REPLACE THE SPOOL INSIDE THE VALVE ASSEMBLY. FOR PUMPS WITH VALVE SUBASSEMBLY DATE CODE 14/11 THE ENTIRE PUMP WILL BE REPLACED. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING JANUARY 2012. OWNERS MAY CONTACT GILLIG SERVICE AT 1-800-735-1500.

Reported: 2014-02-27 (February 27, 2014)

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.

Reported: 2014-06-23 (June 23, 2014)

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.

Reported: 2015-05-05 (May 5, 2015)

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.

Reported: 2015-07-01 (July 1, 2015)

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.

Reported: 2016-01-13 (January 13, 2016)

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.

Reported: 2017-02-24 (February 24, 2017)

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.

Reported: 2018-06-20 (June 20, 2018)

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.