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September 9, 2019 NHTSA CAMPAIGN NUMBER: 19V647000
Loss of Electrical Power at Relay
A stall can increase the risk of a crash.
NHTSA Campaign Number: 19V647
Manufacturer Isuzu
Technical Center of America, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 16,766
Summary
Isuzu Technical Center of America, Inc. (Isuzu) is recalling certain 2017-2019 N-GAS HD and Chevrolet Low Cab Forward 3500 and 4500 vehicles and 2018-2019 Isuzu FTR and Chevrolet Low Cab Forward 6500XD vehicles. The power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to a stall.
Remedy
Isuzu will notify owners, and dealers will inspect the relay box power supply bolt, tightening it as necessary. If the harness or relay box is found to be damaged, it will be replaced or repaired, free of charge. The recall began October 24, 2019. Owners may contact Isuzu customer service at 1-866-441-9638. Isuzu’s number for this recall is V1905.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Check if your Isuzu Truck has a Recall
BULLETIN NUMBER:
CB19-N-002B
ISSUE DATE:
SEPTEMBER 2019
GROUP:
ELECTRICAL
IMPORTANT SAFETY RECALL
RELAY BOX INSPECTION – 19V-647
(Transport Canada 2019-452)
AFFECTED VEHICLES
This bulletin supersedes campaign bulletin CB19-N-002A. This bulletin is being revised to include the sample owner letters for US and Canada. Please discard previous campaign bulletin CB19-N-002A.
INFORMATION
CONDITION
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.
CORRECTION
Isuzu dealers are to inspect and torque the power supply bolt in all affected vehicles. During the inspection, the harness and relay box will be checked for damage and any excess insulation. If there is any excessive insulation, the bolt will be removed, the excess insulation will be trimmed away and the bolt will then be torqued to the appropriate specification. If the harness or relay box is found to be damaged it will be repaired or replaced. This service will be performed free of charge.
VEHICLES INVOLVED
Involved are certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles.
NOTE: It is not necessary to generate a health report in order to submit a warranty claim.
Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry System (IVIS).
For dealers with involved vehicles, a report of involved vehicles containing the complete vehicle identification numbers has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.
PARTS INFORMATION
If the result of the technician’s inspection done in Step 8 of the Service Procedure below directs them to send a photo to the Technical Assistance Line (TAL), additional parts (e.g., harness) may be required to complete this recall. Additional parts may not be ordered without direction and approval from TAL. Dealers are responsible to ensure parts are ordered using the correct affected VIN number. Harnesses mistakenly ordered by a dealer may not be returned.
All harnesses are E MAC coded. After placing a part order for this recall as directed by TAL, please contact TAL to update the TAL case with the appropriate order reference number to have your parts released.
SERVICE PROCEDURE
- Place the vehicle in park, apply the parking brake, and remove the key from the engine control switch.
- Disconnect the negative battery cable.
- If the vehicle is a crew cab model, remove the driver side rear step. (See Figure 1.) If the vehicle is a standard cab, proceed to the next step.
 |
|
Figure 1 1. Bolt |
- Remove the fuse box lid to expose the relays and fuses. (See Figure 2.)
 |
| Figure 2 |
- Remove the three (3) 12mm fuse box mounting bolts and set aside for later use. (See Figure 3.)
 |
| Figure 3 |
- Flip the fuse box over and remove the lower cover using a flat blade screwdriver to release the five (5) locking tabs. Set the lower cover aside for later use. (See Figures 4 and 5.)
 |  |
| Figure 4 | Figure 5 |
- Remove the inner cover by removing the PVC tape, pulling the grommet off the end of the fuse box halves and using the same process to release the locking tabs as in Step 4. Set the cover to the side. (See Figures 6, 7 and 8.)
 |
| Figure 6 |
 |
| Figure 7 |
 |
| Figure 8 |
- Inspect the condition of the relay box power wire. (See Figures 9 and 10 for OK condition.). Determine if there is any damage to the power wire and/or relay box:
- If there is any damage, take a photo similar to Figure 9 and email it to isuzuta@icta-us.com. Then call the Isuzu Technical Assistance Line at 1-877-4783828, Prompt 3 for further instructions. Document the TAL case number on the repair order. This will be required for claim submission.
- If there is no evidence of damage from heat, continue to Step 9.
- If there is any damage, take a photo similar to Figure 9 and email it to isuzuta@icta-us.com. Then call the Isuzu
- Inspect the wire terminal for excessive insulation. (See Figures 10 and 11.) If the insulation is OK, proceed to Step 11. If the insulation is Not OK, proceed to Step 10.
 |
| Figure 9 |
 |  |
| Figure 10 – OK Condition | Figure 11 – Not OK Condition |
- Remove the terminal bolt and lift the terminal away from the fuse box. Using a razor blade, carefully trim away any excess insulation as necessary. Then reinstall the bolt.
- Torque the power supply terminal bolt to the specified torque.
Tightening Torque: 30.1 lb in. (3.4 Nm).
- Reinstall the white inner fuse box cover.
- Reinstall the rubber grommet and tape as necessary.
- Reinstall the fuse box lower cover.
- Mount the fuse box onto the vehicle using the three (3) 12mm mounting bolts removed in Step 5. Tighten the bolts to the specified torque.
Tightening Torque: 5.3 lb ft. (7.1Nm).
- Reinstall the fuse box cover.
- If the vehicle is a crew cab model, reinstall the driver side rear step and torque to the specified torque. (See Figure 1.) For standard cab, proceed to the next step.
Tightening Torque: 13 lb ft. (18 Nm).
- Reinstall the negative battery cable. Tighten the bolts to the specified torque.
Tightening Torque: 53 lb in. (6 Nm).
- Proceed to Applying the Campaign Label.
APPLYING THE CAMPAIGN LABEL
- Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number V1905, Isuzu dealer code, and repair date.
- Affix the campaign label onto the driver’s side B-pillar.
CLAIM INFORMATION
Refer to the Isuzu ICS Claims Processing Manual for details on Campaign Claim Submission. Submit only one claim as indicated below.
If you are seeking reimbursement for completed and unclaimed inspection for the Fuse Box Bolt Dealer Service Campaign (V1904) please use labor code V1905. Submitting for reimbursement will also close this safety recall. The fuse box bolt inspection is only required once and may only be claimed once.
NOTE: It is not necessary generate a health report in order to submit a warranty claim.
| Labor Code | Description | Vehicle Off Road (VOR) Order | Labor Hours |
|---|---|---|---|
| V1905 | Fuse Box Bolt Inspection*
(Includes necessary time to trim harness insulation) ADD: For Crew Cab Vehicles | N/A | 0.5 |
| V1905T | Fuse Box Harness Replacement Per TAL** | Overnight | 0.3 ST |
*Includes 0.1 hours for administrative allowance
**This requires pre-approval from Isuzu TAL. Ensure Step 8 of the service procedure was completed properly by the technician. Failure to receive approval from TAL may result in delayed or no reimbursement.
DEALER RESPONSIBILITY
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of the vehicle, or ownership. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to perform the required correction according to the instructions contained in this bulletin. Program followup cards should not be used for this purpose, since the customers may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service, you must take the steps necessary to ensure the recall remedy has been implemented before selling or releasing the vehicle.
Important:
As required by Federal law, dealers are not to deliver any new vehicle in their inventory, which is covered by a Safety Recall, until the necessary remedy has been performed.
Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry Systems (IVIS). Not all vehicles may be involved.
For dealers with involved vehicles, a listing of involved vehicles containing the complete vehicle identification numbers has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.
OWNER NOTIFICATION
Notification letters will be sent to owners of affected vehicles already retailed in the United States and Canada.
[SAMPLE OWNER LETTER – US]
IMPORTANT SAFETY RECALL
NHTSA Recall 19V-647
This notice applies to your vehicle, <VIN>
OCTOBER 2019
Dear Customer,
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Your vehicle <VIN> <MY> model year Isuzu <SERIES> is involved in safety recall NHTSA 19V-647.
WHAT IS THE CONDITION?
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.
WHAT WE WILL DO
Isuzu dealers are to inspect and torque the power supply bolt in all affected vehicles. During the inspection, the harness and relay box will be checked for damage and any excess insulation. If there is any excessive insulation, the bolt will be removed, the excess insulation will be trimmed away and the bolt will then be torqued to the appropriate specification. If the harness or relay box is found to be damaged it will be repaired or replaced. This service will be performed free of charge.
WHAT YOU SHOULD DO
We recommend that you contact your Isuzu dealer to schedule an appointment. Although not necessary, please present this Owner Notification Letter at the time of your appointment or refer to Campaign Service Bulletin CB19-N-002B. Isuzu estimates that the repair may take up to 48 minutes to perform, but additional time may be necessary. To locate the nearest Isuzu dealer you can visit our website at www.isuzucv.com, click on the dealer locator link and enter your zip code or state. If you do not have access to a computer terminal please contact our Customer Relations Department at the number listed below.
Isuzu Commercial Truck of America
Customer Relations
1-866-441-9638
If you have any difficulty having this recall performed, we recommend that you call Isuzu customer relations at 1-866-441-9638. If you are still not satisfied that we have remedied this situation without charge, and within a reasonable amount of time, you may wish to write to the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the agency’s toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov. We regret any inconvenience which this action may cause you.
Sincerely,
Isuzu Commercial Truck of America, Inc.
Important: If you have sold or traded your Isuzu vehicle, please enter the owner’s name and address, if known, on the attached “Change of Information” postcard, tear off at both perforations, and drop it in the mail. Postage has already been paid. We will contact the new owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Lessor means a person or entity that is the owner, as reflected on the vehicle title, of any five or more leased vehicles.
[SAMPLE OWNER LETTER – CANADA]
IMPORTANT SAFETY RECALL
This notice applies to your vehicle, <VIN>
<MY> model year ISUZU <SERIES>
OCTOBER 2019
Dear Customer,
This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Safety Recall Transport Canada 2019-452.
WHAT IS THE CONDITION?
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.
WHAT WE WILL DO
Isuzu dealers are to inspect and torque the power supply bolt in all affected vehicles. During the inspection, the harness and relay box will be checked for damage and any excess insulation. If there is any excessive insulation, the bolt will be removed, the excess insulation will be trimmed away and the bolt will then be torqued to the appropriate specification. If the harness or relay box is found to be damaged it will be repaired or replaced. This service will be performed free of charge.
WHAT YOU SHOULD DO
We recommend that you contact your Isuzu dealer to schedule an appointment. Although not necessary, please present this Owner Notification Letter at the time of your appointment or refer to Campaign Service Bulletin CB19-N-002B. Isuzu estimates that the repair may take up to 48 minutes to perform, but additional time may be necessary. To locate the nearest Isuzu dealer you can visit our website at www.isuzutruck.ca or contact our Customer Relations Department at the number listed below.
Isuzu Commercial Truck of Canada
Customer Relations
1-866-441-9638
If you have questions or concerns that your Isuzu dealer is unable to answer, please contact our Customer Relations Department at 1-866-441-9638.
We regret any inconvenience which this action may cause you.
Sincerely,
Isuzu Commercial Truck of Canada, Inc.
Important: If you have sold or traded your Isuzu vehicle, please enter the owner’s name and address, if known, on the attached “Change of Information” postcard, tear off at both perforations, and drop it in the mail. Postage has already been paid. We will contact the new owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Lessor means a person or entity that is the owner, as reflected on the vehicle title, of any five or more leased vehicles.
OCTOBER 2019
Safety Recall 19V-647
Campaign Bulletin CB19-N-002B
IMPORTANT SAFETY RECALL
RELAY BOX INSPECTION 19V-647
(Transport Canada 2019-452)
To: Isuzu Commercial Truck Service Managers and Parts Managers
This notice, Campaign Bulletin CB19-N-002B with sample owner letters are being sent to update you about Safety Recall – Relay Box Inspection in certain Isuzu commercial vehicles.
AFFECTED VEHICLES
CONDITION
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.
CORRECTION
Isuzu dealers are to inspect and torque the power supply bolt in all affected vehicles. During the inspection, the harness and relay box will be checked for damage and any excess insulation. If there is any excessive insulation, the bolt will be removed, the excess insulation will be trimmed away and the bolt will then be torqued to the appropriate specification. If the harness or relay box is found to be damaged it will be repaired or replaced. This service will be performed free of charge.
VEHICLES INVOLVED
Involved are certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019.
OWNER NOTIFICATION
OWNER NOTIFICATION WILL BEGIN OCTOBER 25, 2019.
Please ensure that all appropriate personnel within your dealership are aware of this Safety Recall – Relay Box Inspection and that the necessary repairs are performed on all affected vehicles either in your inventory or brought into your dealership for repair per the above instructions.
Isuzu Commercial Truck of America, Inc.
Customer Relations Department
1400 S. Douglass Road, Suite 100, Anaheim, CA 92806 *1-866-441-9638
DOC ID: DN_19V647_20191018
STOP SALE AND DELIVERY – SAFETY RECALL
Date: September 09, 2019
Subject: Stop Sale and Delivery for Upcoming Safety Recall Affected Models:
To: Isuzu Dealer Principal, Sales Manager and Service Manager
Effective immediately, stop the sale and delivery of affected vehicles in your inventory, even if a customer has purchased an affected vehicle. We are in the process of taking steps to address a safety related defect in these vehicles. Federal law prohibits the sale and delivery to customers of any vehicle containing a safety defect. You must not deliver any covered vehicles to customers until after the vehicle has been remedied.
WHAT IS THE CONDITION?
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2018-2019MY Isuzu FTR and 2017-2019MY Isuzu N-Gas vehicles wholesaled on or before 9/9/2019. In some of the affected vehicles, the power supply bolt in the relay box may not have been properly tightened during harness production at the supplier. This may lead to melting of the power wire and/or a loss of electrical power to the vehicle, which can lead to an engine stall. If the bolt is loose, the vehicle could lose electrical power and stall while being driven, increasing the risk of a crash.
WHAT WE WILL DO
Isuzu Commercial Truck of America, Inc. has issued this notice, an affected inventory report (for dealers with involved inventory) and Campaign Bulletin CB19-N-002. The bulletin provides recall remedy instructions. This recall also supersedes the Fuse Box Bolt Dealer Service Campaign (V1904). Vehicles with an “Open” status for campaign V1904 will be reassigned to this new safety recall (V1905).
WHAT YOU SHOULD DO
Confirm the affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and perform the procedure provided Campaign Bulletin CB19-N-002. Vehicles that were inspected as part of dealer service campaign V1904 do not require any further action. If you still need to submit for reimbursement for V1904, please follow the information provided in the Warranty Information section of bulletin CB19-N-002.
IMPORTANT: Always confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry System (IVIS).
You will receive another notice regarding owner notification as well as a version of the campaign bulletin containing a sample owner letter as soon as the owner notification schedule is available and owner letter has been approved by NHTSA.
We regret any inconvenience this action may cause you.
Sincerely,
Isuzu Commercial Truck of America, Inc.
DET-19-126 NHTSA 573- ISUZU RELAY FUSE BOX.
September 9, 2019
Chronology of Defect / Noncompliance Determination
573.6 (c) (6) (7)
| Describe the chronology of events leading up to the defect decision or test data for the noncompliance decision*: (2000) |
| During the summer of 2018, Isuzu received reports of loose main power wire bolts, and/or melted wiring inside the external relay box, on N‐gas trucks. Parts were requested from the field and were then sent to the harness supplier for analysis. An internal investigation was opened under the U.S. field investigation process. As of that time, Isuzu had received a total of nine reports.
In October, 2018, the supplier identified pinched insulation as being the likely cause of damage to the wiring harnesses. The investigation found that, in June, 2017, the supplier had changed the insulator tube heating process from individual heat lamps to a conveyer belt heat lamp system. In January, 2018, the supplier changed back to the individual heat lamp process because workers found that maintaining the proper insulator position was difficult with the conveyor belt heater lamp system. Consistent with the supplier’s analysis, Isuzu In December, based on additional testing, the supplier determined that the pinched insulation was not causing the bolts to loosen. The investigation began to focus on finding the root cause of the loose bolts. Upon review, Isuzu Between January and April, 2019, the supplier conducted extensive testing and evaluation, including a process history review, duplication analysis, a process comparison of the supplier’s different plants, as well as additional wire melting duplication tests. In May, the supplier provided Isuzu Upon reviewing the matter, Isuzu After discussion with the agency, Isuzu However, in late July/early August, Isuzu Isuzu |
13 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| CHEVROLET | LOW CAB FORWARD 3500 | 2017-2019 |
| CHEVROLET | LOW CAB FORWARD 4500 | 2017-2019 |
| CHEVROLET | LOW CAB FORWARD 6500 | 2018-2019 |
| ISUZU | FTR | 2018-2019 |
| ISUZU | N-SERIES | 2017-2019 |
20 Associated Documents
Recall Quarterly Report #1, 2019-4
RCLQRT-19V647-4903.PDF 211.155KB
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Miscellaneous Document- Supplemental Chronology
RMISC-19V647-8361.pdf 586.105KB
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Recall Quarterly Report #2, 2020-1
RCLQRT-19V647-5875.PDF 211.256KB
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Remedy Instructions and TSB
RCRIT-19V647-6430.pdf 409.085KB
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Remedy Instructions and TSB
RCRIT-19V647-6540.pdf 1119.502KB
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Manufacturer Notices(to Dealers,etc)
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ISSUED Owner Notification Letter(Part 577)
RCONL-19V647-1359.pdf 121.355KB
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Manufacturer Notices(to Dealers,etc)
RCMN-19V647-7851.pdf 137.871KB
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Owner Notification Letter(Part 577)
RCONL-19V647-4775.pdf 201.415KB
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Safety Bulletin
RCSB-19V647-1903.pdf 395.051KB
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Manufacturer Notices(to Dealers,etc)
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Manufacturer Notices(to Dealers,etc)
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Recall Acknowledgement
RCAK-19V647-5293.pdf 245.022KB
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Manufacturer Notices(to Dealers,etc)
RCMN-19V647-0989.pdf 233.415KB
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Remedy Instructions and TSB
RCRIT-19V647-8277.pdf 982.506KB
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Defect Notice 573 Report
RCLRPT-19V647-8208.PDF 217.527KB
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Manufacturer Notices(to Dealers,etc)
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Manufacturer Notices(to Dealers,etc)
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Miscellaneous Document- Frequently Asked Questions
RMISC-19V647-9344.pdf 33.988KB
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Recall Quarterly Report #3, 2020-2
RCLQRT-19V647-8640.PDF 211.347KB
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- 【High-Quality Fuses】: Made of a high quality zinc alloy standard and an insulating plastic with a transparent cover, these blade fuses to protect your vehicle from short circuit and overload. The blades are sturdy and won’t break when pulling out.
- 【Wide Application】: Perfect or replacing the blown fuses at any time. This ATC/ATO/APR/ATS fuse kit is widely used in automobiles, trucks, VUS, VTT, UTV, RV, camper, motorcycles, golf carts, ships, snow motorcycles and for most general DC electrical devices including dash camera, radio, lighting, flickering, etc. Highly recommended to check the right size of automotive car fuse before making a purchase.
- 【Easy Use and Identify】: Transparent appearance for quick inspection of fuse conditions, each color of fuse is a specification the Standard Blade Car Fuses Assortment can be easily identified by their color-coded plastic housings and the carved amp rating figures on the top. The car spare fuse kit is packaged in a durable plastic package to protect the car Standard fuse and provide easy transportation and organization.
- [MINI FUSE KIT]: The mini fuses automotive kit includes 120pcs: 2A/3A/5A/7.5A/10A/15A/20A/25A/30A/35A(12PCS of each model ), and equipped with a fuse puller.
- [EASY TO IDENTIFY]: Each type of car fuse with different current specifications is distinguished by different colors. The current specification number is marked at the top of each car fuse assortment kit for easy identification.
- [HIGH QUALITY]: The fuses are made of high-quality zinc alloy, which has the characteristics of corrosion resistance, durability, and high performance. It can timely melt the circuit when the current rises abnormally, protecting the safety of your car and electronic devices.
- [WIDELY USED]: Our mini fuses are suitable for cars, trucks, motorcycles, boats, SUV, ATV,UTV, RVs, Camper RV, etc
- [SATISFACTION FIRST]: If you have any questions, please contact us directly. Customer satisfaction is our purpose.
Last update on 2025-04-19 / Affiliate links / Images from Amazon Product Advertising API
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