2009 NOVA BUS NOVA LFS

SERVICE BRAKES, AIR:SUPPLY:HOSES, LINES/PIPING, AND FITTINGS

Nova Bus (Nova) is recalling certain model year 2009 LFS transit buses manufactured January 1, 2009, to December 31, 2009. In the affected buses, the brake hose fitting crimping ring may have been damaged and, as a result, the crimping ring may fail where the brake hose attaches to the air brake chamber.

Risk: Failure of the crimping rimgs may affect the braking performance, increasing the risk of a crash.

ELECTRICAL SYSTEM:12V/24V/48V BATTERY:CABLES

Nova Bus (Nova) is recalling certain model year 2007-2009 LFS transit buses manufactured January 1, 2007, to December 31, 2009. A power feed cable in the battery compartment may have been incorrectly routed and clipped. As a result, the battery cable may prematurely wear and short to ground.

Risk: A battery cable that shorts to ground increases the risk of a fire.

ELECTRICAL SYSTEM

Nova Bus (Nova) is recalling certain model year 2009 LFS transit buses manufactured January 1, 2009, to December 31, 2009. The affected buses may have an incorrectly wired main power relay circuit, causing the circuit protection to be defeated.

Risk: If the incorrectly wired circuit short circuits, there would be an increased risk of a fire.

POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT

Nova Bus (Nova) is recalling certain model year 2009-2010 LFS transit buses manufactured January 1, 2009, to December 31, 2010 with ZFAV132 rear axles. The affected vehicles may have been produced with rear axle half shafts that received an inadequate surface treatment which may result in axle shaft failure.

Risk: If the axle half shaft fails, the bus would be disabled, increasing the risk of a crash.

SERVICE BRAKES, AIR:ANTILOCK:ABS WARNING LIGHT

Nova Bus is recalling certain model year 2004 and 2006-2013 LFS transit buses. Due to a programming error in the vehicle control unit, the ABS malfunction light may not illuminate if the ABS control unit loses power. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 121, "Air Brake Systems."

Risk: If the ABS malfunction light does not illuminate if the ABS control unit loses power, the driver would not be aware that the ABS is not functional and that the brakes may unexpectedly lock up under certain conditions when the brakes are applied, increasing the risk of crash.

ELECTRICAL SYSTEM

Nova Bus is recalling certain 2009-2012 model year LFS and LFS HEV transit buses equipped with Sure Power DC-DC converters containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found to be capable of conducting electricity after being exposed to heat.

Risk: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

STEERING:LINKAGES:DRAG:LINK:CONNECTION

NOVA BUS IS RECALLING CERTAIN MODEL YEAR 2009 THROUGH 2011 LFS 40 FT AND LFS 60 FT TRANSIT BUSES MANUFACTURED FROM MARCH 31, 2009, THROUGH FEBRUARY 11, 2011. AN INSUFFICIENT TORQUE WAS APPLIED TO THE DRAG LINK ATTACHMENT BOLTS DURING PRODUCTION. THE DRAG LINK COULD BECOME DETACHED FROM THE STEERING LINKAGE, CAUSING A LOSS OF VEHICLE CONTROL.

Risk: LOSS OF VEHICLE CONTROL COULD RESULT IN A CRASH.

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:WHEEL SPEED SENSOR/TONE RING

NOVA BUS IS RECALLING CERTAIN MODEL YEAR 2007-2010 TRANSIT BUSES EQUIPPED WITH ATC (AUTOMATIC TRACTION CONTROL) SYSTEM AND V-BEA MULTIPLEXING SYSTEM MANUFACTURED FROM APRIL 2, 2007 THROUGH JUNE 30, 2010. THE ATC SYSTEM MAY INADVERTENTLY ACTIVATE WHENEVER THE PARKING BRAKE OR THE BRAKE INTERLOCK IS APPLIED, SINCE THE VEHICLE'S MULTIPLEX PROGRAM DID NOT CORRECTLY SEND THE PARKING BRAKE OR INTERLOCK SIGNAL TO THE ATC SYSTEM. THE ATC SYSTEM COULD MISINTERPRET THIS SITUATION AS WHEEL SPIN, SUBSEQUENTLY APPLYING AND RELEASING THE APPLIED BRAKES. THE VEHICLE COULD THEN MOVE UNEXPECTEDLY.

Risk: THE VEHICLE MAY MOVE INADVERTENTLY EVEN WHEN THE PARKING BRAKE IS APPLIED INCREASING THE RISK OF A CRASH.

ENGINE AND ENGINE COOLING

NOVA BUS IS RECALLING CERTAIN MODEL YEAR 2009-2010 NOVA LFS 40 FT AND MODEL YEAR 2010 NOVA LFS 60 FT T-DRIVE TRANSIT BUSES MANUFACTURED FROM AUGUST 27, 2007 THROUGH NOVEMBER 11, 2010, EQUIPPED WITH CUMMINS ISL OR ISB ENGINES. THE BOLTS ON THE ENGINE CRADLE WERE NOT TORQUED ACCORDING TO APPROPRIATE SPECIFICATIONS.

Risk: THE BOLTS CAN BE WORN PREMATURELY AND BREAK OFF, INCREASING THE RISK OF A CRASH.

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

NOVA BUS HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2007-2010 LFS BUSES EQUIPPED WITH MODINE ROOF MOUNTED RADIATOR. THE WRONG TYPE OF O-RING WAS INSTALLED AT THE LOCATIONS BY THE RADIATOR MANUFACTURER, MODINE. THE O-RINGS MUST BE VITON TYPE O-RINGS.

Risk: DETERIORATION OF THESE O-RINGS MAY OCCUR AND LEAKING OR SEEPAGE OF HYDRAULIC OIL.