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November 5, 2021 NHTSA CAMPAIGN NUMBER: 21V861000
Steering Wheel Bolt May Loosen Affecting Steering
An unexpected change in turning radius and difficulty steering can increase the risk of a crash.
NHTSA Campaign Number: 21V861
Manufacturer Isuzu Technical Center of America, Inc.
Components STEERING
Potential Number of Units Affected 5,700
Summary
Isuzu Technical Center of America, Inc. (Isuzu
) is recalling certain 2018-2021 Isuzu
FTR and 2018-2021 Chevrolet
6500XD vehicles. A bolt on the left front steering knuckle may come loose, resulting in an increased turning radius and difficulty steering to the left.
Remedy
Dealers will replace both right and left side stopper bolt jam nuts and clean or replace the extensions, as necessary, free of charge. Owner notification letters were mailed on February 28, 2022. Owners may contact Isuzu customer service at 1-866-441-9638. This recall is an expansion of recall 19V-467. Vehicles previously repaired will need to have the new remedy performed.
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.nhtsa.gov.
Check if your Vehicle has a Recall
CONDITION
Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but we have identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition.
CORRECTION
Isuzu dealers will replace both right and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. This service will be performed free of charge.
VEHICLES INVOLVED Involved are 2018, 2019, 2020 and 2021 model year FTR vehicles.
NOTE: It is not necessary to open a TAL case or generate a health report in order to submit a warranty claim for this campaign.
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 number has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.
PARTS INFORMATION
An initial supply of Stop Bolt Assembly Kits will be shipped to dealers. Additional Stop Bolt Assembly Kits may be ordered from 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 | QTY |
8-97840-619-0 | BOLT; STOP KIT | 2 Kits
*1 for each side |
Chronology of Defect / Noncompliance Determination (amended)
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 2019, Isuzu conducted a safety recall to address field reports of loose steering stopper bolts in FTR model trucks. This recall, 19V-467, was launched in June 2019. The remedy in that recall was to clean the bolt, change the jam nut from a Grade 5 to Grade 8, apply Red Loctite 263 to the bolt, and reinstall with a higher torque specification. The same changes were adopted on the FTR production line in June 2019.
In April 2021, Isuzu received the first Field Product Report (FPR) of this condition in this model vehicle since launching the 2019 recall. The vehicle involved was one produced after the production line change that was made in June 2019. Isuzu
launched an investigation, including researching and identifying warranty claims that may relate to this condition. Isuzu
’s warranty review indicated that the first relevant warranty claim was dated January 20, 2020 and the last was dated September 28, 2021; the majority of the relevant warranty claims were between January 2021 and the end of September 2021.
Some of these reports involved vehicles that had been remedied in the safety recall that launched in 2019, and some involved vehicles that were built after that safety recall.
Isuzu started to collect parts from the field of failed and non-failed parts; all of the non-failed parts and most of the failed parts were from vehicles built after the recall countermeasure was introduced in the factory for newly produced vehicles. Isuzu
studied these returned parts. Isuzu
also conducted a study of varying amounts of Loctite applications on bolts with varying amounts of oil contamination. Isuzu
concluded that, when the Loctite is installed in an adequate amount on a clean bolt, the Loctite application results in breakaway torques that exceed the material properties of the bolt, meaning that the bolt will not loosen. However, the breakaway torque varies with the amount of Loctite applied and the degree of cleanliness of the bolt at the time of the Loctite application.
As a result of its detailed and thorough study of the returned parts, Isuzu concluded that the recall countermeasure (which was also introduced into production) was not sufficient to prevent the left-side steering stopper bolts from loosening. Isuzu
believes that a combination of human errors in cleaning the bolt and in installing the Loctite caused these failures.
Isuzu has received a total of 16 reports of a loose stopper bolt involving 14 unique VINs. Isuzu
is not aware of any crashes or injuries associated with these reports.
On 10/29/2021, Isuzu made a determination to conduct a safety recall to address the issue. Because the production change was identical to the recall remedy for recall 19V-467, and is now believed to be prone to the same risk of human error, Isuzu
will recall all the vehicles included in recall 19V-467, as well as newer vehicles built after the recall countermeasure was introduced into production, for installation of the new Spiralock Nut. This means the vehicle population in this new recall will include all MY 2018 through 2021 FTR vehicles.
8 Affected Products
Vehicles
21 Associated Documents
Manufacturer Notices(to Dealers,etc)
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-7704.pdf 105.736KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-21V861-8538.pdf 97.248KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-6019.pdf 108.209KB
Miscellaneous Document – Chronology
RMISC-21V861-3571.pdf 114.79KB
Recall Acknowledgement
RCAK-21V861-4609.pdf 645.577KB
Defect Notice 573 Report
RCLRPT-21V861-8644.PDF 215.663KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-8874.pdf 239.692KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-21V861-2419.pdf 310.609KB
Recall 573 Report – Amendment 11/23/2021
RCLRPT-21V861-3858.PDF 215.726KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-4087.pdf 111.181KB
Miscellaneous Document
RMISC-21V861-4227.pdf 175.581KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-0094.pdf 732.641KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V861-5480.pdf 276.223KB
Remedy Instructions and TSB
RCRIT-21V861-1742.pdf 755.837KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V861-7858.pdf 104.561KB
Manufacturer Notices(to Dealers,etc)
ISSUED Owner Notification Letter(Part 577)
RCONL-21V861-7319.pdf 114.547KB
Recall Quarterly Report #1, 2022-1
RCLQRT-21V861-3382.PDF 211.155KB
Recall Quarterly Report #2, 2022-2
RCLQRT-21V861-3580.PDF 211.25KB
Recall Quarterly Report #3, 2022-3
RCLQRT-21V861-0399.PDF 211.333KB
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SEOCONTENT-START
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 2019, Isuzu conducted a safety recall to address field reports of loose steering stopper bolts in FTR model trucks. This recall, 19V-467, was launched in June 2019. The remedy in that recall was to clean the bolt, change the jam nut from a Grade 5 to Grade 8, apply Red Loctite 263 to the bolt, and reinstall with a higher torque specification. The same changes were adopted on the FTR production line in June 2019. In April 2021, Isuzu received the first field report of this condition in this model vehicle since launching the 2019 recall. The vehicle involved was one produced after the production line change that was made in June 2019. Isuzu continued to receive additional reports of loose left-side steering stopper bolts over the summer and early autumn of 2021. Some of these reports involved vehicles that had been remedied in the safety recall that launched in 2019, and some involved vehicles that were built after that safety recall. Isuzu started to collect parts from the field of failed and non-failed parts; all of the non-failed parts and most of the failed parts were from vehicles built after the recall countermeasure was introduced in the factory for newly produced vehicles. Isuzu studied these returned parts. Isuzu also conducted a study of varying amounts of Loctite applications on bolts with varying amounts of oil contamination. Isuzu concluded that, when the Loctite is installed in an adequate amount on a clean bolt, the Loctite application results in breakaway torques that exceed the material properties of the bolt, meaning that the bolt will not loosen. However, the breakaway torque varies with the amount of Loctite applied and the degree of cleanliness of the bolt at the time of the Loctite application. As a result of its detailed and thorough study of the returned parts, Isuzu concluded that the recall countermeasure (which was also introduced into production) was not sufficient to prevent the left-side steering stopper bolts from loosening. Isuzu believes that a combination of human errors in cleaning the bolt and in installing the Loctite caused these failures. Isuzu has received a total of 16 reports of a loose stopper bolt involving 14 unique VINs. Isuzu is not aware of any crashes or injuries associated with these reports. On 10/29/2021, Isuzu made a determination to conduct a safety recall to address the issue. Because the production change was identical to the recall remedy for recall 19V-467, and is now believed to be prone to the same risk of human error, Isuzu will recall all the vehicles included in recall 19V-467, as well as newer vehicles built after the recall countermeasure was introduced into production, for installation of the new Spiralock Nut. This means the vehicle population in this new recall will include all MY 2018 through 2021 FTR vehicles.
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IMPORTANT SAFETY RECALL NHTSA Recall 21 V-861 This notice applies to your vehicle, DECEMBER 2021 Dear Customer: This notice is sent to you in accor~ents of the National Traffic and Motor Vehicle Safety Act. Your 2018 model year F-Series vehicle, VIN—-is involved in safety recall 21 V-861. WHAT IS THE CONDITION Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left ttm1s, which could make it difficult to make sharp ttm1s. If the vehicle’s tlU11ing radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. For this reason, even if you obtained the remedy in that prior recall, you need to plan to participate in this campaign as well. We are working hard to secure replacement parts to repair your vehicle, as set forth below. Unfortunately, parts are not yet available. We will notify you once parts become available and ask you to bring your vehicle to an Isuzu dealer at that time. WHAT WE WILL DO Isuzu dealers will replace one or more parts of both the right and left side stopper bolt assemblies, which will include a newly designed Jam Nut. This service will be perfonned free of charge. PARTS ARE NOT CURRENTLY AVAILABLE for this remedy. We are working as quickly as possible to obtain the necessary parts. When parts become available, we will send you another notice. WHAT WE WILL DO Please pay special attention to the tlll1ling radius of your vehicle and allow additional clearance when making sharp left tlm1s. If at any point before you receive the second notice you believe your vehicle is having a problem with its ttmring radius in left tlU11s, please promptly contact your dealer to schedule an appointment. Present this Owner Notification Letter and/or mention recall number 21 V-861 at the time of your appointment. The dealer will check to detennine whether there is a problem with the stopper bolts. If the dealer finds that the stopper bolt is causing a problem with your vehicle’s steering, the dealer will contact Isuzu Cormnercial Tmck of America to obtain instmctions for a temporary repair and will then implement that temporary repair. However, you will still need to bring your vehicle back to the dealer after you receive a letter notifying you that the remedy parts have become available. If you have any questions or concems, please call Isuzu Customer Relations at 1-866-441-9638. If you are still not satisfied, you may 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: l-800-424-9153), or go to http://www.safercar.gov. We regret any inconverrience which this action may cause you. Sincerely, Isuzu Commercial Tmck 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 n 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. r Tearhere 7 DODD-DOD (00D)~uoqd □□□□□ ~ □□ ~ □□□□□□□□□□□□□□ ~ □□□□□□□□□□□□□□□□□□□□□□□□ SS~lppy □□□□□□□□□□□□□□□□□□□□□□□□ ~~ NOLLVWllO.!INI ssmmav .M.3N l 98·A li Z1V:JtJH l,afvs IJOH .1.addo1s HJ,d >10([ -;-;-u~101s 0 ssa.1ppv / dJqs.1aUMO Jo aauvq:J nzns1 BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 106 ANAHEIM, CA L Tear here _j POSTAGE WILL BE PAID BY ADDRESSEE l11111111111111•1111l1l1111111111l11ll•111•11l11l111•l111•l11111• ISUZU COMMERCIAL TRUCK, INC. CUSTOMER RELATIONS PO BOX 66011 ANAHEIM CA 92816-9900 ISUZU ISUZU COMMERCIAL TRUCK OF AMERICA, INC. 1400 SOUTH DOUGLASS ROAD SUITE 100 ANAHEIM, CA 92806 II I I II 1 ••••••••••••• AUTO•• ALL FOR AADC 190 IMPORTANT SAFETY RECALL INFORMATION Issued in Accordance With Federal Law ***** l11l11ll···1 11 111·111111·1·l1111l11111··1•11·1·11·l111111·1l111·1 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES PRESORTED FIRST CLASS U.S. Postage PAID Whittier, CA Permit No. 175 u.s. Department Of Tranopof1atton NHTSA – .::Z::aov SAFETY RECALL NOTICE
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IMPORTANT SAFETY RECALL NHTSA Recall 21 V-861 This notice applies to yow- vehicle, FEBRUARY 2022 Dear Customer: This notice is sent to you in accordance :wi1b_the ·eouirement.s of the National Traffic and Motor Vehicle Safety Act. Your 2018 model year F-Se1ies vehicle, VIN _______ …. is involved in safety recall 21 V-861. WHAT IS CONDITION Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the stee1ing stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make shrup turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A p1ior recall (I 9V-467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. For this reason, even if you obtained the remedy in that prior recall, you need to plan to prut icipate in this campaign as well. Previously, we sent you a letter about this safety recall on your 2018 model yeru· F-Series vehicle. This letter is to info1m you that pruts ru·e now available. CORRECTION Isuzu dealers will replace both 1ight and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. This se1vice will be perfo1med free of charge. WHAT YOU SHOULD DO We recommend that you contact your Isuzu dealer to schedule an appointment. Although not necessa1y, please present this Owner Notification Letter at the time of your appointment or refer to Campaign Se1vice Bulletin CB22-E-00 1. We estimate that the repair may take up to 54 minutes to pe1fo1m. Additional time may be necessa1y depending on how appointments ru·e scheduled and processed at your dealership. To locate the neru·est Isuzu dealer you can visit our website at www.isuzucv.com or contact our Customer Relations Deprutment at the number listed below. Isuzu Commercial Truck of America Customer Relations 1-866-441-9638 If you ru·e still not satisfied, you may w1ite 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: l -800-424-9153), or go to www.safercar.gov. We regret any inconvenience which this action may cause you. Sincerely, Isuzu Commercial Tmck of Ame1ica, 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 n 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. r Tearhere 7 DODD-DOD (00D)~uoqd □□□□□ ~ □□ ~ □□□□□□□□□□□□□□ ~ □□□□□□□□□□□□□□□□□□□□□□□□ SS~lppy □□□□□□□□□□□□□□□□□□□□□□□□ ~~ NOLLVWllO.!INI ssmmav .M.3N l98-Ali zdH [ssv IJOH do1s Suμaa,s HLd >10([ -;-;-u~101s 0 ssa.1ppv / dJqs.1aUMO Jo aauvq:J nzns1 BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 106 ANAHEIM, CA L Tear here _j POSTAGE WILL BE PAID BY ADDRESSEE l111111 11111111•1••1l1l1111111111l1•ll•111•1•l11l111•l111•l11111• ISUZU COMMERCIAL TRUCK, INC. CUSTOMER RELATIONS PO BOX 66011 ANAHEIM CA 92816-9900 ISUZU ISUZU COMMERCIAL TRUCK OF AMERICA, INC. 1400 SOUTH DOUGLASS ROAD SUITE 100 ANAHEIM, CA 92806 II I I II IMPORTANT SAFETY RECALL INFORMATION 11·111•11 ··1·11 11 1·11111 11111111·111111111111·h111l1l11···1l1l·I Issued in Accordance With Federal Law ***** NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES PRESORTED FIRST CLASS U.S. Postage PAID Whittier, CA Permit No. 175 U.S. Department of Transpot1atton NHTSA SAFETY RECALL NOTICE
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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_21V861_20211227 DECEMBER 2021 Safety Recall 21V-861 (NHTSA) / 2021-679 (TC) IMPORTANT SAFETY RECALL FTR STEERING STOP JAM NUT REPLACEMENT – 21V-861 (Transport Canada 2021-679) To: Isuzu Commercial Truck Service Managers and Parts Managers This notice along with sample Interim Owner Letters are being sent to update you about new Safety Recall – FTR Steering Stop Jam Nut Replacement in certain Isuzu commercial vehicles. AFFECTED VEHICLES 2018-2021MY Isuzu F-Series Vehicles WHAT IS THE CONDITION? Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but we have identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. We are working hard to secure replacement parts. Unfortunately, parts are not yet available. We will notify you once parts become available. WHAT ACTIONS ARE BEING AND WILL BE TAKEN When parts become available, Isuzu dealers will replace one or more parts of both the right and left side stopper bolt assemblies, which will include a newly designed Jam Nut. This service will be performed free of charge. For now, the Interim Owner Letter will encourage owners/drivers to pay special attention to the turning radius of their vehicle and allow additional clearance when making sharp left turns. If at any point before they receive the second owner letter (parts available), an owner believes their vehicle is having a problem with its turning radius during left turns, the Interim Owner Letter encourages the owner to promptly contact their Isuzu dealer to schedule an appointment. In that event, you (dealers) are to inspect whether there is a problem with the stopper bolts in the vehicle. If it is determined that a stopper bolt is causing a problem with a vehicle’s steering, you (dealers) are to contact the Isuzu Technical Assistance Line to obtain instructions for a temporary repair, and then implement that temporary repair per those instructions (NOTE: Warranty reimbursement details will be outlined in the instructions at that time). However, please note that owners will still need to bring their vehicle back to their Isuzu dealer after they receive the second owner letter notifying them that the remedy parts have become available. INTERIM OWNER NOTIFICATION INTERIM OWNER NOTIFICATION WILL BEGIN DECEMBER 29, 2021. Please ensure that all appropriate personnel within your dealership are aware of this new Safety Recall – FTR Steering Stop Jam Nut Replacement.
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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_V2106_20211105 STOP SALE AND DELIVERY – SAFETY RECALL Date: November 05, 2021 Subject: Stop Sale and Delivery for Upcoming Safety Recall Affected Models: 2018-2021MY Isuzu FTR Vehicles 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, 2019, 2020 and 2021 model year FTR vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. (A prior recall (19V-467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition.) WHAT WE WILL DO We are preparing a new service procedure and procuring parts to repair these vehicles. You will receive another notice regarding owner notification and campaign bulletin release as soon as the schedule is available. WHAT YOU SHOULD DO For affected vehicles in dealer inventory, open a repair order referencing this Stop Sale and hold the vehicles until further notification is received. We regret any inconvenience which this action may cause you. Sincerely, Isuzu Commercial Truck of America, Inc.
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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_a_21V861_20220222 FEBRUARY 2022 Safety Recall 21V-861 (NHTSA) / 2021-679 (TC) IMPORTANT SAFETY RECALL FTR STEERING STOP BOLT ASSEMBLY REPLACEMENT – 21V-861 (Transport Canada 2021-679) To: Isuzu Commercial Truck Service Managers and Parts Managers This notice and Campaign Bulletin CB22-E-001 (with sample owner letters) are being sent to update you about new Safety Recall – FTR Steering Stop Bolt Assembly Replacement in certain Isuzu commercial vehicles. AFFECTED VEHICLES 2018-2021MY Isuzu F-Series Vehicles CONDITION Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but we have identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. CORRECTION Isuzu dealers will replace both right and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. This service will be performed free of charge. PARTS An initial supply of required parts will be shipped to dealers and are expected to be delivered prior to the owner notification date. OWNER NOTIFICATION OWNER NOTIFICATION WILL BEGIN FEBRUARY 28, 2022. Please ensure that all appropriate personnel within your dealership are aware of this new Safety Recall – FTR Steering Stop Bolt Assembly Replacement. IMPORTANT SAFETY RECALL FTR STEERING STOP BOLT ASSEMBLY REPLACEMENT – 21V-861 (Transport Canada 2021-679) 2018-2021MY Isuzu FTR Vehicles This campaign supersedes previous Safety Recall 19V-467 (TC 2019-306). Even if a vehicle was repaired under the previous recall, it will need to be repaired in accordance with the new service procedure in this Campaign Bulletin. Please discard previous campaign bulletin CB19-E-001. CONDITION Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but we have identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. CORRECTION Isuzu dealers will replace both right and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. This service will be performed free of charge. VEHICLES INVOLVED Involved are 2018, 2019, 2020 and 2021 model year FTR vehicles. NOTE: It is not necessary to open a TAL case or generate a health report in order to submit a warranty claim for this campaign. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Isuzu Vehicle Inquiry System (IVIS). AFFECTED VEHICLES INFORMATION IMPORTANT SERVICE INFORMATION FOR: SERVICE MANAGER SERVICE ADVISOR TECHNICIAN PARTS DEPARTMENT WARRANTY PERSONNEL BULLETIN NUMBER: CB22-E-001 ISSUE DATE: FEBRUARY 2022 GROUP: SUSPENSION & STEERING CV 2 For dealers with involved vehicles, a report of involved vehicles containing the complete vehicle identification number has been or will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned. PARTS INFORMATION An initial supply of Stop Bolt Assembly Kits will be shipped to dealers. Additional Stop Bolt Assembly Kits may be ordered from 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 QTY 8-97840-619-0 BOLT; STOP KIT 2 Kits *1 for each side Stop Bolt Kit Components 1. Adapter Base 2. Spiralock Nut 3. Stop Bolt 1. Apply the parking brake and block the rear wheels. 2. Start the engine and turn the steering wheel all the way to the left in order to access the right (passenger side) Stop Bolt Assembly. (See Figure 1.) Shut the engine off after turning the steering wheel. SERVICE PROCEDURE 3 Figure 1 – Right Front Stop Bolt Assembly 3. Remove the Stop Bolt Assembly using a 1” deep well socket. 4. Use an engineer’s ruler to measure the distance that the Stop Bolt protrudes out from the Adapter Base. (See Figure 2.) Record this measurement. Discard the old Stop Bolt Assembly. If the Stop Bolt and/or Jam Nut are loose, disregard this measurement. The Steering Angle Adjustment will need to be performed after installing the new Stop Bolt Kit. Figure 2 5. Install the new Adapter Base using a 1” socket as shown in Figure 3. Tighten the Adapter Base to the specified torque. Tightening Torque: 190 N•m (140 lb ft). 4 Figure 3 6. Assemble the new Stop Bolt and Spiralock Nut into the new Adapter Base as shown in Figure 4 and tighten the Spiralock Nut only hand tight. Figure 4 a. If the Stop Bolt and Jam Nut were not found to be loose in Step 4, adjust the Stop Bolt until it is the same distance from the adaptor base measured and recorded in Step 4 (use a ½” open end wrench as necessary). When adjusted properly, snug the Spiralock Nut with a ¾” open wrench. Using a ¾” deep well socket and a torque wrench, tighten the Spiralock Nut to the specified torque. Proceed to Step 7. Tightening Torque: 165 N•m (122 lb ft). 5 b. If the Stop Bolt and Jam Nut were found to be loose in Step 4, use the TEMPLATE FOR STEERING BOLT ADJUSTMENT located after Step 10 below and Skip to Steps 11 through 17 in this bulletin in order to perform the STEERING ANGLE ADJUSTMENT. Then return to Step 7. 7. Using a white, yellow or other colored paint pen, paint a line across the Spiralock Nut and Adapter Base to indicate that the Spiralock Nut has been torqued. After installing the right (passenger side) Stop Bolt Kit, proceed to Step 8. After both right and left (passenger and driver side) Stop Bolt Kits are installed, torqued and adjusted as necessary, proceed to Step 10. 8. Start the engine and turn the steering wheel all the way to the right in order to access the left (driver side) Stop Bolt Assembly. (See Figure 1.) Shut the engine off after turning the steering wheel. 9. Repeat Steps 3 through 7 to install the left (driver side) Stop Bolt Kit. 10. Proceed to Step 18 “Applying the Campaign Label”. 6 Print the template for the steering bolt adjustment. Cut out one template for use. The remaining templates may be used on future applications. TEMPLATE FOR STEERING BOLT ADJUSTMENT 7 STEERING ANGLE ADJUSTMENT 11. Per the instructions in the applicable Work Shop Manual (WSM), safely tilt the cab and install the safety lock pin. 12. Press the template over the upper kingpin grease fitting at the mark indicated. Orientate the template as shown in Figure 5. Make sure the area on the template marked “Tire” is parallel with the tire as shown. Figure 5 13. Start the engine and turn the steering wheel in the opposite direction of the wheel/stop bolt being replaced. Continue to turn the steering wheel until the template installed in Step 12 is in the same position as in Figure 6. The 50° dashed line on the template should align parallel with the casting mark through the center of the axle. Then turn the engine off. 8 Figure 6 14. Using a ½” open-end wrench, adjust the stop bolt until the stop bolt contacts firmly against the axle bolt stop. (See Figure 7.) Ensure the template is still in the position shown in Figure 6. Figure 7 9 15. Tighten the Stop Bolt Spiralock Nut with a ¾” open-end wrench. Start the engine again and turn the steering wheel in the opposite direction to access the steering stop. Turn off the engine. Use a ¾” deep well socket and a torque wrench to tighten the Stop Bolt Spiralock Nut to the specified torque. (See Figure 8.) Tightening Torque: 165 N•m (122 lb ft). Figure 8 16. Remove the template from the kingpin grease fitting and discard. 17. Per the instructions in the applicable WSM, remove and properly stow the safety lock pin and tilt the cab back down. Ensure the cab is locked into place. Return to Step 7. APPLYING THE CAMPAIGN LABEL 18. Using a ball-point pen, fill in a campaign label (Part No. 2-90028-700-0) with Campaign Number 21V-861 (US) or 2021-679 (Canada), Isuzu dealer code, and repair date. 19. Affix the campaign label onto the driver’s side B-pillar. 10 CLAIM INFORMATION Refer to the Isuzu ICS Claims Processing Manual for details on Campaign Claim Submission. Submit only one claim as indicated below. NOTE: It is not necessary to open a TAL case or generate a health report in order to submit a warranty claim for this campaign. Labor Code Description Labor Hours V2106 Replace Left & Right Stop Bolt Assemblies ADD: Steering Angle Adjustment 0.5 0.4 *Includes 0.1 hours for administrative allowance DEALER RESPONSIBILTY 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 make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. 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 number 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 (see enclosed copies). 11 [SAMPLE OWNER LETTER – US] IMPORTANT SAFETY RECALL NHTSA Recall 21V-861 This notice applies to your vehicle, <VIN> FEBRUARY 2022 Dear Customer, This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Your <model year> model year F-Series vehicle, VIN <VIN> is involved in safety recall 21V-861. WHAT IS THE CONDITION? Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (19V-467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. For this reason, even if you obtained the remedy in that prior recall, you need to plan to participate in this campaign as well. Previously, we sent you a letter about this safety recall on your <MY> model year F-Series vehicle. This letter is to inform you that parts are now available. WHAT WE WILL DO Isuzu dealers will replace both right and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. 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 CB22-E-001. We estimate that the repair may take up to 54 minutes to perform. Additional time may be necessary depending on how appointments are scheduled and processed at your dealership. 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 If you are still not satisfied, you may 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 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. 12 [SAMPLE OWNER LETTER – CANADA] IMPORTANT SAFETY RECALL This notice applies to your vehicle, <VIN> <MY> model year ISUZU F-SERIES FEBRUARY 2022 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 2021-679. WHAT IS THE CONDITION? Isuzu Motors Limited has decided that a defect, which relates to motor vehicle safety, exists in 2018, 2019, 2020 and 2021 model year F-Series vehicles. The jam nut for the steering stopper bolt on the left side may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns, which could make it difficult to make sharp turns. If the vehicle’s turning radius is increased, there is an increased risk of a crash. A prior recall (2019-306) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. For this reason, even if you obtained the remedy in that prior recall, you need to plan to participate in this campaign as well. Previously, we sent you a letter about this safety recall on your <MY> model year F-Series vehicle. This letter is to inform you that parts are now available. WHAT WE WILL DO Isuzu dealers will replace both right and left side stopper bolt assemblies, which include new Spiralock Nuts, and torque the new Spiralock Nut to a new specification. 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 CB22-E-001. We estimate that the repair may take up to 54 minutes to perform. Additional time may be necessary depending on how appointments are scheduled and processed at your dealership. To locate your nearest dealer please use the dealer locator on our website at www.isuzutruck.ca. If you have questions or concerns, 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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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-861 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Isuzu Technical Center of America, Inc. Submission Date : NOV 05, 2021 NHTSA Recall No. : 21V-861 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Isuzu Technical Center of America, Inc. Address : 46401 Commerce Center Drive Plymouth MI 48170-2473 Company phone : 866-441-9638 Population : Number of potentially involved : 5,700 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2021 ISUZU FTR Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The vehicle population begins with 2018 MY Start of Production. Population end date is the last date of production for each make 2021 MY vehicle. The new Spiralock nut was introduced into production at the start of production for the 2022 MY. Production Dates : MAY 08, 2017 – APR 19, 2021 VIN Range 1 : Begin : 54DK6S165JSG00023 End : 54DK6S167MSG70188 ✔ Not sequential Vehicle 2 : 2018-2021 Chevrolet 6500XD Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The vehicle population begins with 2018 MY Start of Production. Population end date is the last date of production for each make 2021 MY vehicle. The new Spiralock nut was introduced into production at the start of production for the 2022 MY. Production Dates : OCT 31, 2017 – SEP 18, 2020 VIN Range 1 : Begin : 54DKFS163JSG00926 End : 54DKFS165MSG50179 ✔ Not sequential Part 573 Safety Recall Report 21V-861 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : On certain vehicles, the jam nut for the steering stopper bolt on the left-front knuckle may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns. A change in turning radius could make it difficult to make sharp turns. A prior recall (19V467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the vehicle’s turning radius is increased, there is an increased risk of a crash. Description of the Cause : NR Identification of Any Warning that can Occur : Drivers experience difficulty turning the steering wheel fully to the left. Involved Components : Component Name 1 : Stop Bolt; Adapter Component Description : Steering stopper bolt assembly Component Part Number : 8983956790 Supplier Identification : Component Manufacturer Name : Dana Corporation Address : NR NR Country : NR Chronology : Provided chronology as uploaded document Part 573 Safety Recall Report 21V-861 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Isuzu dealers will replace both right and left side stopper bolt jam nuts with the new Spiralock Nut. The bolts and extensions will be cleaned and/ or replaced as required. / No reimbursement is anticipated as it is expected that all of the affected vehicles are still under warranty or subject to the prior recall (19V457). How Remedy Component Differs from Recalled Component : Unlike the recalled components and the remedy employed in the prior recall, the new remedy involves the addition of a Spiralock Nut and no longer requires the use of Loctite. Identify How/When Recall Condition was Corrected in Production : Production of the MY 21 FTR ended in April 2021. When production of the 22 MY FTR began in the week of October 4, 2021, the new stopper bolt assemblies (using the Spiralock Nut) were installed as standard equipment. Recall Schedule : Description of Recall Schedule : Isuzu and Chevrolet will notify their respective vehicle owners and dealers of this recall. Owners will be informed that the recall repairs will be done free of charge. The recall (owner notification) is expected to begin December 29, 2021. For additional information, Isuzu owners may contact 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. Planned Dealer Notification Date : NOV 05, 2021 – NOV 05, 2021 Planned Owner Notification Date : DEC 29, 2021 – JAN 04, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-861 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Isuzu Technical Center of America, Inc. Submission Date : NOV 23, 2021 NHTSA Recall No. : 21V-861 Manufacturer Recall No. : V2106 Manufacturer Information : Manufacturer Name : Isuzu Technical Center of America, Inc. Address : 46401 Commerce Center Drive Plymouth MI 48170-2473 Company phone : 866-441-9638 Population : Number of potentially involved : 5,700 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2021 ISUZU FTR Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The vehicle population begins with 2018 MY Start of Production. Population end date is the last date of production for each make 2021 MY vehicle. The new Spiralock nut was introduced into production at the start of production for the 2022 MY. Production Dates : MAY 08, 2017 – APR 19, 2021 VIN Range 1 : Begin : 54DK6S165JSG00023 End : 54DK6S167MSG70188 ✔ Not sequential Vehicle 2 : 2018-2021 Chevrolet 6500XD Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : The vehicle population begins with 2018 MY Start of Production. Population end date is the last date of production for each make 2021 MY vehicle. The new Spiralock nut was introduced into production at the start of production for the 2022 MY. Production Dates : OCT 31, 2017 – SEP 18, 2020 VIN Range 1 : Begin : 54DKFS163JSG00926 End : 54DKFS165MSG50179 ✔ Not sequential Part 573 Safety Recall Report 21V-861 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : On certain vehicles, the jam nut for the steering stopper bolt on the left-front knuckle may loosen and allow the bolt to back away from the steering knuckle. This could result in an increase in the turning radius of the vehicle in left turns. A change in turning radius could make it difficult to make sharp turns. A prior recall (19V467) was conducted to address this issue, but Isuzu has identified this condition on vehicles that were remedied in that campaign as well as those that were produced after a change in production intended to prevent the condition. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the vehicle’s turning radius is increased, there is an increased risk of a crash. Description of the Cause : NR Identification of Any Warning that can Occur : Drivers experience difficulty turning the steering wheel fully to the left. Involved Components : Component Name 1 : Stop Bolt; Adapter Component Description : Steering stopper bolt assembly Component Part Number : 8983956790 Supplier Identification : Component Manufacturer Name : Dana Corporation Address : Vía Monterrey-Matamoros 608 Paseo de las Flores Monterrey Foreign States 66626 Country : Mexico Chronology : Provided chronology as uploaded document. Part 573 Safety Recall Report 21V-861 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Isuzu dealers will replace both right and left side stopper bolt jam nuts with the new Spiralock Nut. The bolts and extensions will be cleaned and/ or replaced as required. / No reimbursement is anticipated as it is expected that all of the affected vehicles are still under warranty or subject to the prior recall (19V457). How Remedy Component Differs from Recalled Component : Unlike the recalled components and the remedy employed in the prior recall, the new remedy involves the addition of a Spiralock Nut and no longer requires the use of Loctite. Identify How/When Recall Condition was Corrected in Production : Production of the MY 21 FTR ended in April 2021. When production of the 22 MY FTR began in the week of October 4, 2021, the new stopper bolt assemblies (using the Spiralock Nut) were installed as standard equipment. Recall Schedule : Description of Recall Schedule : Isuzu and Chevrolet will notify their respective vehicle owners and dealers of this recall. Owners will be informed that the recall repairs will be done free of charge. The recall (owner notification) is expected to begin December 29, 2021. For additional information, Isuzu owners may contact 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. Planned Dealer Notification Date : NOV 05, 2021 – NOV 05, 2021 Planned Owner Notification Date : DEC 29, 2021 – JAN 04, 2022 * NR – Not Reported
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