V2103 Rear Axle U-bolt Nuts Inspection – 2015-2021 Isuzu

March 19, 2021 NHTSA CAMPAIGN NUMBER: 21V194000

Rear Axle U-Bolt Not Properly Tightened

The misalignment may cause the propeller shaft to separate, causing a loss of power to the rear wheels and a stall, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V194

Manufacturer Isuzu Technical Center of America, Inc.

Components SUSPENSION

Potential Number of Units Affected 258

 

Summary

Isuzu Technical Center of America, Inc. (Isuzu) is recalling certain 2015-2017 Isuzu NPR, Reach, 2016-2020 Isuzu NPR XD, NPR HD, NQR, 2016-2021 Isuzu NRR, 2017-2020 Chevrolet 4500XD, 4500HD, 5500HD, and 2020 Chevrolet 5500XD vehicles. The U-bolt nuts for the rear axle may not have been properly tightened and may loosen, causing the axle to misalign.

 

Remedy

Isuzu will notify owners, and dealers will inspect and, if needed, replace and tighten the rear axle U-bolt nuts, free of charge. The recall began on April 23, 2021. Owners may contact Isuzu customer service at 1-866-441-9638. Isuzu’s number for this recall is V2103.

 

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:
CB21-F-001

ISSUE DATE:
MARCH 2021

GROUP:
SUSPENSION

 

IMPORTANT SAFETY RECALL
REAR AXLE U-BOLT NUTS INSPECTION – 21V-###
(Transport Canada 2021-###)

 

AFFECTED VEHICLES

MY	Model	No. of Affected Vehicles
2015-2017	NPR Diesel Vehicles	3
2015-2017	NPR Stripped Chassis (Reach Van)	7
2016-2020	NPRHD Diesel Vehicles	27
2016-2020	NPRXD Diesel Vehicles	15
2016-2020	NQR Diesel Vehicles	29
2016-2021	NRR Diesel Vehicles	93

 

This bulletin supersedes campaign bulletin CB21-F-001A. This bulletin has been updated to include US and Canada owner letters. Please discard previous campaign bulletin CB21-F-001A.

 

INFORMATION

CONDITION

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2021MY Isuzu N-Series Diesel vehicles. In the affected vehicles, the U-bolt nuts for the rear axle may not have been properly tightened at the manufacturing plant.  The U-bolts and U-Bolt nuts secure the rear axle to the leaf spring.  If the U-Bolt nuts loosen, the axle will initially be held in place by the leaf spring centering pin.  With continued use, the axle can misalign with the centering pin, allowing the rear axle to move rearward and the propeller shaft to separate at its slip joint.  If the propeller shaft separates, the rear wheels will not receive power from the engine and the vehicle will stall, increasing the risk of a crash.

 

CORRECTION

Isuzu dealers will inspect the rear U-bolt nuts. If any of the rear U-bolt nuts do not pass the inspection, the rear U-bolts, U-bolt nuts and washers (if applicable) are to be replaced. This service will be performed free of charge.

 

VEHICLES INVOLVED

Involved are certain 2015-2021MY N-Series Diesel Vehicles

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

If the Service Procedure below directs the technician to replace the U-Bolts per Step 6.a., parts should be ordered on a VOR (Vehicle Off Road) Order. Make sure you order the part numbers and quantities applicable to the specific vehicle model(s) according to the information below.

Model	Part Number	Description	Quantity
NPR NPRHD NPRXD	8-94127-924-3	U-Bolt	4
	8-97360-118-0	Washer	8
	8-97360-121-0	Nut	8
NQR NRR	8-98128-783-0	U-Bolt	4
	1-09440-039-1	Nut	8
NPR (Reach VAN)	8-94412-505-0	U-Bolt	4
	8-97360-118-0	Washer	8
	8-97360-121-0	Nut	8

 

SERVICE PROCEDURE

 

1. Shift vehicle to park, turn off engine, set parking brake, and block rear wheels. 2. Locate the rear axles U-bolt mounting nuts. (See Figure 1.)

 

2. Locate the rear axles U-bolt mounting nuts. (See Figure 1.)

 

3. Using a rag or wire brush clean the U-Bolt nuts and retainer plate surface.

 

4. Use a paint pen or small brush and paint to make an alignment mark on each nut, washer (if equipped), and the retainer plate in a straight vertical line as shown in Figures 2 & 3.

 

5. Use a torque wrench to tighten all eight (8) rear axle U-bolt nuts to 100 Nm (74 lb ft).

 

6. Inspect the painted alignment marks on all eight (8) rear axle U-bolt nuts.
   1. If ANY of the painted marks are no longer aligned (See Figure 4), proceed to Step 7 to replace the U-bolts and U-bolt nuts.
   2. If ALL eight (8) of the rear axle U-bolt nut paint marks are still aligned (See Figure 2), proceed to Applying the Campaign Label.

 

U-BOLTS AND U-BOLT NUTS REPLACEMENT

7. Loosen and remove the two (2) right hand side/forward rear axle nuts and washers (if applicable). (See Figure 5.) Lift the old U-bolt upwards to remove it.

 

8. Install a new U-bolt in the same location from which the old U-bolt was removed in Step 7 Make sure the U-bolt is properly seated as shown in Figure 6.

 

9. Place the two (2) new washers (if applicable) and two (2) new nuts onto the new U-bolt. Use hand tools to lightly tighten each nut evenly.

 

10. Use a torque wrench to alternately tighten the nuts to the specification shown in Table 1 below.

 

Vehicle Model	Tightening Torque
NPR/NPRHD/NPRXD/Reach Van	177 Nm (131 lb ft)
NQR/NRR	284 Nm (210 lb ft)
Table 1

 

IMPORTANT: Ensure the U-Bolt and U-bolt nuts are properly seated and tightened evenly so the U-bolt does not tilt.

 

11. Measure the amount of U-bolt thread protruding from the U-bolt nut (A) and record your (See Figure 7.)

 

12. Measure the amount of U-bolt thread protruding from the U-bolt nut (B) and record your measurement. (See Figure 7.)

 

13. Determine the difference between measurements (A) and (B). The result should be 5mm or less.
    1. If the difference between measurement (A) and (B) is 5mm or less, proceed to Step 14
    2. If the difference between measurement (A) and (B) is greater than 5mm, loosen both nuts and repeat Step 10 – 13.

IMPORTANT: The difference between measurements A and B must be 5mm or less.

 

14. After replacing all four (4) U-bolts, proceed to Applying the Campaign Label.

   

APPLYING THE CAMPAIGN LABEL

15. Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number V2103, Isuzu dealer code, and repair date.

 

16. 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
V2103	U-Bolt Torque Inspection Only	0.4*
V2103R	U-Bolt Torque Inspection & Replacement	1.3*

 

*Includes 0.1 hours for administrative allowance.

 

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.

[SAMPLE OWNER LETTER – US] 

IMPORTANT SAFETY RECALL

NHTSA Recall 21V-194

This notice applies to your vehicle, <VIN>

APRIL 2021

 

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 N-Series diesel vehicle  is involved in safety recall NHTSA 21V194.

 

WHAT IS THE CONDITION?

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20152021MY Isuzu N-Series Diesel vehicles. In the affected vehicles, the U-bolt nuts for the rear axle may not have been properly tightened and may loosen, causing the axle to misalign. The misalignment may cause the propeller shaft to separate, causing a loss of power to the rear wheels and a stall, increasing the risk of a crash.

 

WHAT WE WILL DO

Isuzu dealers will inspect and, if needed, replace and tighten the rear axle U-bolt nuts. 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 CB21-F-001B. We estimate that the inspection may take 24 minutes to perform. However additional time may be required if the rear axle U-bolt nuts need to be replaced. 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 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.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 N-SERIES

 

APRIL 2021

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 2021-168.

 

WHAT IS THE CONDITION?

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20162020MY Isuzu N-Series Diesel vehicles. In the affected vehicles, the U-bolt nuts for the rear axle may not have been properly tightened and may loosen, causing the axle to misalign. The misalignment may cause the propeller shaft to separate, causing a loss of power to the rear wheels and a stall, increasing the risk of a crash.

 

WHAT WE WILL DO

Isuzu dealers will inspect and, if needed, replace and tighten the rear axle U-bolt nuts. 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 CB21-F-001B. We estimate that the inspection may take 24 minutes to perform. However additional time may be required if the rear axle U-bolt nuts need to be replaced. 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.

 

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STOP SALE AND DELIVERY – SAFETY RECALL

Date: March 19, 2021 

Subject: Stop Sale and Delivery for Upcoming Safety Recall

Affected Models: (Total 174 Vehicles)

 

MY	Model	No. of Affected Vehicles
2015-2017	NPR Diesel Vehicles	3
2015-2017	NPR Stripped Chassis (Reach Van)	7
2016-2020	NPRHD Diesel Vehicles	27
2016-2020	NPRXD Diesel Vehicles	15
2016-2020	NQR Diesel Vehicles	29
2016-2021	NRR Diesel Vehicles	93

 

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 20152021MY Isuzu N-Series Diesel vehicles. In the affected vehicles, the U-bolt nuts for the rear axle may not have been properly tightened at the manufacturing plant.  The U-bolts and U-bolt nuts secure the rear axle to the leaf spring.  If the U-bolt nuts loosen, the axle will initially be held in place by the leaf spring centering pin. With continued use, the axle can misalign with the centering pin, allowing the rear axle to move rearward and the propeller shaft to separate at its slip joint.  If the propeller shaft separates, the rear wheels will not receive power from the engine and the vehicle will stall, increasing the risk of a crash.

 

WHAT WE WILL DO

Isuzu Commercial Truck of America, Inc. and Isuzu Commercial Truck of Canada, Inc. have issued this notice, an affected inventory report (for dealers with involved inventory) and Campaign Bulletin CB21-F-001, which provides the recall remedy instructions.

 

WHAT YOU SHOULD DO

Confirm the affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and perform the remedy procedure set forth Campaign Bulletin CB21-F-001.

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 revised campaign bulletin containing sample owner letters once they have been approved by NHTSA and Transport Canada.

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_V2103_20210319

 

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APRIL 2021

Safety Recall NHTSA 21V-194 / TC 2021-168

Campaign Bulletin CB21-F-001B

IMPORTANT SAFETY RECALL

REAR AXLE U-BOLT NUTS INSPECTION – 21V-194

(Transport Canada 2021-168)

 

To: Isuzu Commercial Truck Service Managers and Parts Managers

This notice, and revised Campaign Bulletin CB21-F-001B with sample owner letters, are being sent to update you about Safety Recall – Rear Axle U-Bolt Nuts Inspection in certain Isuzu commercial vehicles.

 

AFFECTED VEHICLES

MY	Model	No. of Affected Vehicles
2015-2017	NPR Diesel Vehicles	3
2015-2017	NPR Stripped Chassis (Reach Van)	7
2016-2020	NPRHD Diesel Vehicles	27
2016-2020	NPRXD Diesel Vehicles	15
2016-2020	NQR Diesel Vehicles	29
2016-2021	NRR Diesel Vehicles	93

 

CONDITION

Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in certain 20152021MY Isuzu N-Series Diesel vehicles. In the affected vehicles, the U-bolt nuts for the rear axle may not have been properly tightened at the manufacturing plant.  The U-bolts and U-bolt nuts secure the rear axle to the leaf spring.  If the U-bolt nuts loosen, the axle will initially be held in place by the leaf spring centering pin. With continued use, the axle can misalign with the centering pin, allowing the rear axle to move rearward and the propeller shaft to separate at its slip joint.  If the propeller shaft separates, the rear wheels will not receive power from the engine and the vehicle will stall, increasing the risk of a crash.

 

CORRECTION

Isuzu dealers will inspect the rear U-bolt nuts. If any of the rear U-bolt nuts do not pass the inspection, the rear U-bolts, U-bolt nuts and washers (if applicable) are to be replaced. This service will be performed free of charge.

 

OWNER NOTIFICATION

OWNER NOTIFICATION WILL BEGIN APRIL 23, 2021.

Please ensure that all appropriate personnel within your dealership are aware of this Safety Recall – Rear Axle U-Bolt Nuts 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_21V194_20210419

 

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573_ISUZU_N-SERIES_V2103_CHRONOLOGY

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)

Isuzu received two field reports – one dated November 18, 2020 and the other dated December 7, 2020 – indicating that the trucks were found to have loose or missing rear U-bolts.  In one case, which was reported at 3432 miles of service, the driver noticed that the rear axle had moved out of place.  In the other case, which was reported at 559 miles of service, the propeller shaft disengaged.  Both vehicles were towed to the dealership. Isuzu has not received any other reports of this condition either from the U.S. or other markets.   A review of production records at the Fujisawa plant found that, with regard to both vehicles, the U-bolt nut tightening process for the front axles had been completed near the close of business on a Friday and the multi-nut runner had been turned off for the weekend.  When restarted the next week, the multi-nut runner should have displayed a “1,” signaling that more of the U-bolt nuts required tightening, but instead showed a “0,” indicating that no more tightening was needed.  As a result, the vehicles were shipped without the rear U-bolt nuts having been properly tightened.   Isuzu determined that the issue does not affect the front U-bolt nuts because those nuts are installed differently than the rear U-bolt nuts.  The U-bolt nuts for the front axle are temporarily installed by hand and left loose.  If not subsequently tightened, there would be a large gap noticeable by the line worker and/or the quality inspector.  In contrast, the U-bolt nuts for the rear axles are preliminarily installed by an impact wrench to the point where the nuts are seated.  As a result, there is not a noticeable difference at the factory between a properly tightened and a potentially loose U-bolt nut on the rear axle.   On December 14, 2020, Isuzu implemented an interim countermeasure at the plant to preclude line workers from turning off the multi-nut runner and thus preventing the tool from providing misleading information to the workers at the next morning shift.  On December 18, 2020, Isuzu changed the program coding on the tool to ensure that the instructions provided to the line workers are saved.   Isuzu then undertook a detailed review of past production records to determine whether or not there were, or may have been, additional vehicles shipped with loose rear U-bolt nuts.  Isuzu reviewed records starting with the date upon which the current multi-nut runner was used at the plant (May 7, 2015) until December 14, 2020.  Isuzu identified a number of vehicles for which no records affirmatively confirming the proper tightening of the rear U-bolt nuts could be found – 258 of which were shipped to the US market. Many of the affected vehicles have been in service for a significant amount of time, and the service manual specifies periodic inspection and retorquing of the U-bolt nuts; therefore, it is likely that the U-bolt nuts on the rear axles of the subject vehicles will be found to be properly tightened.  But since Isuzu could not confirm through production records that the rear axle U-bolt nuts were, in fact, properly tightened at the production plant, it determined on March 12, 2021 to conduct a safety recall to inspect and, if needed, tighten the rear axle U-bolt nuts.

 

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40 Affected Products

Vehicles

MAKE	MODEL	YEAR
CHEVROLET	4500HD	2017-2020
CHEVROLET	4500XD	2017-2020
CHEVROLET	5500HD	2017-2020
CHEVROLET	5500XD	2020
ISUZU	NPR	2015-2017
ISUZU	NPR HD	2016-2020
ISUZU	NPR XD	2016-2020
ISUZU	NQR	2016-2020
ISUZU	NRR	2016-2021
ISUZU	REACH	2015-2017

 

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17 Associated Documents

Miscellaneous Document- Chronology

RMISC-21V194-6065.pdf 682.729KB

 

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Recall Acknowledgement

RCAK-21V194-4251.pdf 646.27KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V194-6556.pdf 116.153KB

 

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Remedy Instructions and TSB

RCRIT-21V194-2816.pdf 460.745KB

 

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Defect Notice 573 Report

RCLRPT-21V194-8479.PDF 221.924KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V194-4872.pdf 100.933KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V194-3452.pdf 11.643KB

 

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Remedy Instructions and TSB

RCRIT-21V194-5211.pdf 340.579KB

 

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Remedy Instructions and TSB

RCRIT-21V194-9117.pdf 486.487KB

 

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Remedy Instructions and TSB

RCRIT-21V194-9606.pdf 1309.835KB

 

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Owner Notification Letter(Part 577)

RCONL-21V194-1270.pdf 277.872KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V194-0575.pdf 57.111KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V194-1365.pdf 395.902KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V194-3092.pdf 24.438KB

 

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Recall Quarterly Report #2, 2021-3

RCLQRT-21V194-9264.PDF 211.257KB

 

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V194-1469.PDF 211.344KB

 

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V194-0968.PDF 211.157KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V194&docType=RCL

 

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