V2004 – Ground Cable Replacement – 2018-2021 Isuzu FTR

September 11, 2020 NHTSA CAMPAIGN NUMBER: 20V554000

Ground Cable On Starter Motor May Break

If the cable is broken and repeated attempts are made to start the vehicle, the starter may ground through the steel braiding of the power steering hose, allowing it to heat up and possibly rupture, increasing the risk of a fire.

 

NHTSA Campaign Number: 20V554

Manufacturer Isuzu Technical Center of America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 4,352

 

Summary

Isuzu Technical Center of America, Inc. (Isuzu) is recalling certain 2018-2021 FTR and Chevrolet 6500XD vehicles. The ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, resulting in an engine no-crank or slow-crank condition, causing the vehicle not to start.

 

Remedy

Isuzu and Chevrolet will notify their respective owners and dealers to replace the ground cable and to inspect and replace the power steering hose is damage exists, free of charge. The recall began October 9, 2020. Isuzu owners may contact the Isuzu Customer Relations at 1-866-441-9638 and Chevrolet owners may contact the GM Medium Duty Truck assistance line at 1-800-862-4389. Isuzu’s number for this recall is V2004.

 

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

 

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BULLETIN NUMBER:
CB20-N-002A

ISSUE DATE:
SEPTEMBER 2020

GROUP:
ELECTRICAL

 

IMPORTANT SAFETY RECALL

GROUND CABLE REPLACEMENT – 20V-###
(Transport Canada 2020-###)

 

AFFECTED VEHICLES

• 2018-2021MY Isuzu FTR Vehicles Produced Before 8/14/2020

This bulletin supersedes service bulletin CB20-N-002. This bulletin is being revised to add information for completing customer vehicles. The procedure for repairing NEW vehicles in dealer inventory remains unchanged. Please discard previous bulletin CB20-N-002.

 

INFORMATION

CONDITION

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2018-2021MY Isuzu FTR vehicles produced before August 14, 2020. In the affected vehicles, the ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, which can result in an engine no-crank or slow-crank condition, causing the vehicle not to start.  If the driver attempts to start the engine after the cable has broken, electrical current will flow through the steel braiding of the power steering hose rather than through the broken cable, generating heat within the power steering hose.  Once the cable is broken, if the driver makes repeated efforts to restart the engine or if the key is held in the engine start position for an extended period of time, enough heat may be generated to melt and potentially to rupture the power steering hose.  If the power steering hose ruptures, power steering fluid may leak onto a hot engine or exhaust surface increasing the risk of a fire.

 

CORRECTION

For Customer Vehicles: Isuzu dealers will replace the ground cable in all affected vehicles and will inspect the power steering hose for any damage. The power steering hose will be replaced if the ground cable was broken or if the power steering hose is bulging/swelling or leaking. This service will be performed free of charge.

For Affected New Vehicles in Dealer Inventory: Isuzu dealers will replace only the ground cable.

 

VEHICLES INVOLVED

Involved are certain 2018-2021MY Isuzu FTR vehicles produced before August 14, 2020.

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using IVIS (Isuzu Vehicle Information System).

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

Dealers will be shipped an initial quantity of parts in order to complete immediate repairs. Additional parts orders may be placed with American Isuzu Parts Distribution Network (AIPDN). Please refer to your “involved vehicles listing” before ordering parts. Normal (non-emergency) orders should be placed on a Stock Order. In an emergency situation, parts should be ordered on a VOR (Vehicle Off Road) Order.

Part Number	Description	Quantity
8-97663-264-0	Starter Earth Cable	1

 

If the result of the technician’s inspection done in Step 5 of the Service Procedure below directs them to send a photo to the Technical Assistance Line (TAL), the power steering hose may require replacement to complete this recall. The power steering hose (8-98212-319-0) may not be ordered without direction and approval from TAL. Dealers are responsible to ensure parts are ordered using the correct affected VIN number.

 

SERVICE PROCEDURE

1. Place the vehicle in park, apply the parking brake, turn the engine off and block the rear tires.
2. At the right side of the vehicle, close to rear of the front tire, locate the ground cable. See Figure 1.

Figure 1

 

3. Remove the bolt from the frame end of the ground cable. See Figure 2.

Figure 2

 

4. Remove the bolt from the starter end of the ground cable. See Figure 3.

Figure 3

 

5. Did the ground cable break during removal, or was it found broken when removed?
   • If the ground cable breaks or is found broken, take a photo of it and email it to isuzuta@icta-us.com. Order a replacement power steering hose, and after obtaining the order reference number, call the Isuzu Technical Assistance Line at 1-877-478-9828, Prompt 3. Provide the part number and order reference number and TAL will confirm and approve the replacement of the power steering hose (898212-319-0). Document the TAL case number on the repair order. This will be required for claim submission. Continue to Step 6.
   • If the ground cable is not broken and does not break during removal, continue to Step 6.
6. Clean the area of the frame and the starter where the ground cable is mounted. Remove any rust or dirt that may interfere with the connection.
7. Using the bolt removed in Step 4 above, first attach the eyelet of the new ground cable closest to the part number label to the starter. Ensure that the flat side of the eyelet is flush to the starter housing; Torque to 40 Nm (30 ft.lb.). See Figure 4.

Figure 4

 

8. Using the bolt removed in Step 3 above, attach the new ground cable to the frame. Ensure that the flat side of the eyelet is flush to the frame; Torque to 20 Nm (15 ft.lb.).
9. Ensure that the ground cable is installed and routed as shown in Figure 5.

Figure 5

 

10. Paint the bolt heads with a high-visibility paint marker after proper torque has been completed. See Figure 6.

Figure 6

 

11. If the ground harness broke upon removal or was found broken in Step 5, continue to the Power Steering Hose Replacement section in this bulletin to complete the campaign. If the ground harness was not broken, proceed to Step 12.
12. Check the last 9 digits of the VIN against the VIN table below. If the VIN is included in the table, continue to the Power Steering Hose Replacement section in this bulletin to complete the campaign. If VIN is NOT included in the table, proceed to Step 13.

0JSG00964	4JSG00904	6JSG00046	9JSG00106
1JSG00679	5JSG00183	6JSG00502	XJSG00194
2KSG00627	5JSG00913	8JSG00503	XJSG00518

 

13. Inspect the power steering hose (no.3), shown in Figure 8, for unusual bulging/swelling or leaking from the rubber flexible section of the hose.
    • If the power steering hose is bulging/swelling or leaking, take a photo of it and email it to isuzuta@icta-us.com. Order a replacement power steering hose, and after obtaining the order reference number, call the Isuzu Technical Assistance Line at 1-877-478-9828, Prompt 3. Provide the part number and order reference number, and TAL will confirm and approve the replacement of the power steering hose (8-98212-319-0). Document the TAL case number on the repair order. This will be required for claim submission. Continue to the Power Steering Hose Replacement section in this bulletin to complete this campaign.
    • If the hose is not bulging/swelling or leaking, proceed to the Applying the Campaign Label section in this bulletin.

NOTE: The power steering hose should be replaced ONLY if (a) the starter ground cable was found broken or broke upon removal, or (b) the power steering hose was bulging/swelling or leaking.

 

POWER STEERING HOSE REPLACEMENT

14. Remove the right side noise cover from the frame by removing the five (5) bolts. Set the bolts aside for reuse later. See Figure 7.

Figure 7

 

15. Place a drain pan under the power steering hose frame union fitting.

NOTE: Be sure to use a wrench to hold the solid pipe fitting so it does not turn when loosening the hose nuts.

16. Remove the lower power steering hose nut (no. 2) from the power steering pump pipe. See Figure 8.
17. Remove the upper power steering hose nut (no. 1) from the frame union. See Figure 8.
18. Remove the power steering hose from the vehicle.

Figure 8

 

IMPORTANT:  The power steering hose must not be twisted or bent during installation. Do not bend or distort the hose to make installation easier. Failure to follow these procedures could result in damage to the hose.

19. Route the new power steering hose in the same position the old hose occupied prior to removal.
20. Smoothly route the new power steering hose in order to avoid sharp bends and kinking.

NOTE: Be sure to use a wrench to hold the solid pipe fitting so it does not turn when tightening the hose nuts.

21. Install the lower power steering hose nut (no. 2) to the power steering pump pipe. Tighten the hose to 49-74 N·m (36-55 lb ft). See Figure 8.
22. Install the upper power steering hose nut (no. 1) to the frame union. Tighten the hose to 49-74 N·m (36-55 lb ft). See Figure 8.
23. Fill the power steering system to the proper level indicated on the power steering reservoir using Dexron VI fluid only.
24. Install the right side noise cover onto the frame using the five (5) bolts set aside in Step 13. Tighten the bolts to 20.0 N·m (14 lb·ft). See Figure 7.
25. Remove the drain pan from under the vehicle.
26. Start the engine, and bleed the air from the power steering system. Top off the power steering reservoir using Dexron VI fluid.
27. Proceed to Applying the Campaign Label.

 

APPLYING THE CAMPAIGN LABEL

1. Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number V2004, Isuzu dealer code, and repair date.
2. 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.

Labor Operation Code	Description	Labor Time
V2004	Ground Cable Replacement Safety Recall ADD for P/S Hose Replacement	0.5*

 

*Includes 0.1 hours for administrative allowance.

N.P.N. to be used only when the power steering hose is replaced. Amount covers up to 1 liter of power steering fluid.

 

DEALER RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign 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 follow-up 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 campaign 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 IVIS (Isuzu Vehicle Information System). 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

Sample recall letters that will be sent to owners of affected vehicles already retailed in the United States and Canada will be added in a future bulletin revision.

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[SAMPLE OWNER LETTER – US]

IMPORTANT SAFETY RECALL

NHTSA Recall 20V-554

This notice applies to your vehicle, <VIN>

OCTOBER 2020

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 FTR is involved in safety recall NHTSA 20V-554.

 

WHAT IS THE CONDITION?

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182021MY Isuzu FTR vehicles produced before August 14, 2020. In the affected vehicles, the ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, which can result in an engine no-crank or slow-crank condition, causing the vehicle not to start. If the driver attempts to repeatedly start the engine after the cable has broken or holds key in the start position for an extended period of time, electrical current will flow through the steel braiding of the power steering hose, rather than through the broken cable, generating heat within the power steering hose. Enough generated heat may potentially damage or rupture the power steering hose. If the power steering hose ruptures, power steering fluid may leak onto a hot engine or exhaust surface increasing the risk of a fire.

 

WHAT WE WILL DO

Isuzu dealers will replace the ground cable in all affected vehicles and will inspect the power steering hose for any damage. The power steering hose will be replaced if it is found to be damaged or, even in the absence of any apparent damage, if the ground cable was broken. 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 CB20N-002A. We estimate that the repair may take up to 30 minutes to perform. However, additional time may be necessary due to the dealer’s schedule and/or if power steering hose replacement is necessary. To locate the nearest Isuzu dealer you can visit our website at www.isuzucv.com or contact our Customer Relations Department at the number listed below.

Isuzu Commercial Truck of America
Customer Relations
1-866-441-9638

 

REIMBURSEMENT

If you have already paid for repairs to address the condition covered by this safety recall, you may be eligible to have those costs reimbursed. The enclosed form explains the terms under which reimbursement may be available and how to request reimbursement.

 

If you have any difficulty having this recall performed, we recommend that you call Isuzu customer relations at 1866-441-9638. 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.nhtsa.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.

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[SAMPLE OWNER LETTER – CANADA]

IMPORTANT SAFETY RECALL

This notice applies to your vehicle, <VIN>

<MY> model year ISUZU FTR

OCTOBER 2020

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 2020-429.

 

WHAT IS THE CONDITION?

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182021MY Isuzu FTR vehicles produced before August 14, 2020. In the affected vehicles, the ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, which can result in an engine no-crank or slow-crank condition, causing the vehicle not to start. If the driver attempts to repeatedly start the engine after the cable has broken or holds key in the start position for an extended period of time, electrical current will flow through the steel braiding of the power steering hose, rather than through the broken cable, generating heat within the power steering hose. Enough generated heat may potentially damage or rupture the power steering hose. If the power steering hose ruptures, power steering fluid may leak onto a hot engine or exhaust surface increasing the risk of a fire.

 

WHAT WE WILL DO

Isuzu dealers will replace the ground cable in all affected vehicles and will inspect the power steering hose for any damage. The power steering hose will be replaced if it is found to be damaged or, even in the absence of any apparent damage, if the ground cable was broken. 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 CB20N-002A. We estimate that the repair may take up to 30 minutes to perform. However, additional time may be necessary due to the dealer’s schedule and/or if power steering hose replacement is 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

 

REIMBURSEMENT

If you have already paid for repairs to address the condition covered by this safety recall, you may be eligible to have those costs reimbursed. The enclosed form explains the terms under which reimbursement may be available and how to request reimbursement.

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.

 

Isuzu Commercial Truck Customer Relations
1400 S. Douglass Road, Suite 100 Anaheim, CA  92806
Reimbursement questions should be directed to the following number:
1-866-441-9638
Or Email: cvcs@icta-us.com

 

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OCTOBER 2020

Safety Recall NHTSA 20V-554 / TC 2020-429

Campaign Bulletin CB20-N-002A

 

IMPORTANT SAFETY RECALL

GROUND CABLE REPLACEMENT – 20V-554

(Transport Canada 2020-429)

 

To: Isuzu Commercial Truck Service Managers and Parts Managers

This notice and Campaign Bulletin CB20-N-002A with sample owner letters are being sent to update you about Safety Recall – Ground Cable Replacement in certain Isuzu commercial vehicles.

 

AFFECTED VEHICLES

• 2018-2021MY Isuzu FTR Vehicles Produced Before August 14, 2020

 

CONDITION

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20182021MY Isuzu FTR vehicles produced before August 14, 2020. In the affected vehicles, the ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, which can result in an engine no-crank or slow-crank condition, causing the vehicle not to start. If the driver attempts to repeatedly start the engine after the cable has broken or holds key in the start position for an extended period of time, electrical current will flow through the steel braiding of the power steering hose, rather than through the broken cable, generating heat within the power steering hose. Enough generated heat may potentially damage or rupture the power steering hose. If the power steering hose ruptures, power steering fluid may leak onto a hot engine or exhaust surface increasing the risk of a fire.

 

CORRECTION

For Customer Vehicles: Isuzu dealers will replace the ground cable in all affected vehicles and will inspect the power steering hose for any damage. The power steering hose will be replaced if the ground cable was broken or if the power steering hose is bulging/swelling or leaking. This service will be performed free of charge.

For New Vehicle Dealer Inventory: Isuzu dealers will replace only the ground cable.

 

OWNER NOTIFICATION

OWNER NOTIFICATION WILL BEGIN OCTOBER 09, 2020.

Please ensure that all appropriate personnel within your dealership are aware of this Safety Recall – Ground Cable Replacement 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_20V554_20201005

 

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STOP SALE AND DELIVERY – SAFETY RECALL

Date: September 11, 2020 

Subject: Stop Sale and Delivery for Upcoming Safety Recall

Affected Models: 

• 2018-2021MY Isuzu FTR Vehicles Produced Prior to August 14, 2020

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 20182021MY Isuzu FTR vehicles produced before August 14, 2020. In the affected vehicles, the ground cable connecting the starter motor to the vehicle frame may break at the starter-side eyelet, which can result in an engine no-crank or slow-crank condition, causing the vehicle not to start.  If the driver attempts to start the engine after the cable has broken, electrical current will flow through the steel braiding of the power steering hose rather than through the broken cable, generating heat within the power steering hose.  Once the cable is broken, if the driver makes repeated efforts to restart the engine or if the key is held in the engine start position for an extended period of time, enough heat may be generated to melt and potentially to rupture the power steering hose.  If the power steering hose ruptures, power steering fluid may leak onto a hot engine or exhaust surface increasing the risk of a fire.

 

WHAT WE WILL DO

Isuzu Commercial Truck of America, Inc. has issued this notice, Campaign Bulletin CB20-N-002 and, if applicable, an affected inventory report (approximately 330 vehicles are in dealer inventory). Dealers will be shipped an initial quantity of part number 8-97663-264-0 today, September 11, 2020, in order to complete immediate repairs. 

 

WHAT YOU SHOULD DO

After confirming there are affected vehicles in your dealer’s inventory, using the Isuzu Vehicle Information System (IVIS), open a repair order referencing this Stop Sale for each affected NEW vehicle in your inventory and replace the ground cable only on NEW vehicles per the service procedure in the campaign bulletin.

IMPORTANT: Always confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Information System (IVIS).

You will receive another notice when the owner notification schedule has been finalized.  At that time, sample owner letters and a second service procedure, which calls for the inspection and, if necessary, replacement, of the power steering hose in customer-owned and used (affected) vehicles, will be added to the campaign bulletin.

We regret any inconvenience this action may cause you.

Sincerely,

Isuzu Commercial Truck of America, Inc.

Isuzu Commercial Truck of America, Inc.
Customer Relations Department
1400 S. Douglass Road, Suite 100, Anaheim, CA 92806 *1-866-441-9638

DOC ID: SS_V2004_20200911

 

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DET-20-130  573 – ISUZU FTR STARTER GROUND CABLE

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)

 

In June 2019, Isuzu received a report of a MY 2018 FTR truck having been towed to a dealership in April due to a no-start condition.  The customer reported seeing smoke from the engine compartment and the Technical Assistance Report described a hole in the power steering hose.  In July 2019, Isuzu received another report of a no-start condition with a melted power steering hose.  Review of the returned part from the first report found that the starter ground cable had broken at the starter side terminal eyelet.  The cable was internally corroded and the power steering hose was ruptured near one of the end fittings.  A US-based investigation was opened through Isuzu North America

 

Corporation’s (INAC) internal investigation process and a corollary investigation was begun at Isuzu Motor Limited (IML) in Japan.

 

Isuzu collected healthy ground cables from the field for further analysis, and continued to collect parts associated with reported failures.  In late August 2019, Isuzu received a report of a no-start condition with excessive resistance.  The occurrence differed from the prior instances in that this claim mentioned slow cranking and there was no damage found to the power steering hose.  As the investigation progressed, Isuzu received six additional reports of no-start conditions during the remainder of 2019, with five of those not indicating degradation to the power steering hose.  Isuzu was collecting healthy (non-failure) ground cables, and conducting analyses, through which it determined that the starter ground cables were subject to excessive stress.  By the end of 2019, Isuzu directed its Engineering group to consider replacing the specification for the ground starter cable to reduce the stress and to prevent the no-start condition.

 

Between January and March, 2020, Isuzu conducted evaluations with a proposed replacement supplier.  By the end of March, however, that supplier informed Isuzu that it lacked capacity to service Isuzu’s needs.  A new supplier was identified in April and further development of a new starter ground cable began and was completed as of June 11, 2020.  Before initiating a field action, Isuzu reviewed the field experience.  Isuzu had received an additional eight reports of a no-start condition, all requiring replacement of the starter ground cable and three of which also involved replacing the power steering hose.  In one of those cases, the driver reported seeing smoke from the back of the cab.  Further investigation of the relationship between the ground starter cable issue and the power steering hose issue was necessary.

 

When initial internal investigation was found inconclusive, returned parts were sent to the supplier for destructive testing.  Additional investigation was also conducted internally.  The results of that testing were reported on July 30, 2020.  Although the supplier concluded that the power steering hose failures might have been caused by the use of low grade power steering fluid, Isuzu’s analysis suggested that under a starter ground cable open circuit condition, the electrical current could flow instead through the steel braiding of the power steering hose during cranking and increase the temperature of the steel braiding. Under certain conditions, the temperature could increase to a level causing damage to the power steering hose.

 

Based on its analysis, Isuzu determined that damage to the power steering hose is a secondary impact from the no-start condition caused by a failed starter ground cable.  Isuzu therefore initiated a change on the production line on August 14^th, 2020 to utilize a longer starter ground cable with a larger bend radius and L-shaped retainers.  Isuzu also prepared to conduct a field action to replace the starter ground cable in all field vehicles.  In reviewing the field campaign, it was noted that the potential for the power steering hose to degrade, melt and rupture is dependent on the driver continuing to try to restart the truck from a no-start condition or holding the key in the engine start position for an extended period of time.  To the extent that power steering fluid may leak onto a hot surface and lead to smoke, the smoke is readily apparent to the driver and the driver would cease trying to start the engine. The issue arises only in the circumstance of a no-start condition and not while the vehicle is in motion.  Isuzu has not received any reports that a power steering hose leak did, and does not believe that such a leak would, move beyond a thermal event to an actual flame.  Nonetheless, due to the nature of the issue and out of an abundance of caution, Isuzu decided on September 3, 2020 to conduct the field campaign as a safety recall.

 

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8 Affected Products

Vehicles

MAKE	MODEL	YEAR
CHEVROLET	6500XD	2018-2021
ISUZU	FTR	2018-2021

 

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22 Associated Documents

Remedy Instructions and TSB

RCRIT-20V554-8140.pdf 604.598KB

 

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Manufacturer Notices(to Dealers,etc)- Frequently Asked Questions

RCMN-20V554-8128.pdf 36.678KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-6176.pdf 36.123KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-3237.pdf 120.485KB

 

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Remedy Instructions and TSB

RCRIT-20V554-3999.pdf 597.282KB

 

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Remedy Instructions and TSB

RCRIT-20V554-2571.pdf 1221.435KB

 

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Remedy Instructions and TSB

RCRIT-20V554-0924.pdf 876.41KB

 

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Miscellaneous Document-Chronology

RMISC-20V554-0727.pdf 657.411KB

 

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Recall Acknowledgement

RCAK-20V554-9514.pdf 244.921KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-7225.pdf 229.245KB

 

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Defect Notice 573 Report

RCLRPT-20V554-1626.PDF 215.856KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-3751.pdf 68.097KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V554-4759.pdf 289.35KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-2942.pdf 62.946KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-7626.pdf 36.123KB

 

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V554-0199.PDF 211.155KB

 

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V554-5952.PDF 211.257KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V554-4962.pdf 91.564KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-4158.pdf 61.383KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V554-8245.pdf 107.657KB

 

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Recall Quarterly Report #3, 2021-2

RCLQRT-20V554-9624.PDF 211.347KB

 

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Recall Quarterly Report #4, 2021-3

RCLQRT-20V554-1996.PDF 211.446KB

 

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https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V554&docType=RCL

 

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