The following is a summary of NHTSA motorcoach recalls since the beginning of 2015:
An exhaust clamp at the turbocharger could prematurely fail on some 2009-2013 Volvo 9700 motorcoaches, allowing hot exhaust gases to leak and potentially ignite materials inside the engine compartment.
A missing coolant line clip in various 2011-2016 Prevost models could permit the coolant line to rub against a braided fuel line.
Loss of control
On a range of 2010-2016 Van Hool coaches, front steering knuckle carriers from certain production batches did not meet minimum strength requirements and could crack and “lose functionality.” A total failure could cause a wheel to separate from the coach. Remedies depend upon each part’s production batch and ultrasonic testing.
Seven 2016 Prevost H3-45, H3-VIP, and X3-45VIP coaches with independent front suspension were fitted with grade 8.8 mounting studs from a supplier that “may not meet their ISO specification. The bolts have an ultimate yield lower than required by the design specification. If the studs fail, the wheel may pivot in the direction of braking force moment, which may increase the risk of a crash.”
The front sway bar on certain 2014-2016 MCI J4500 coaches may potentially fail, cracking at one of the bushing/clamp locations and adversely affecting vehicle handling.
Steering gearbox bracket fasteners could become loose on some 2018-2016 Temsa TS35C coaches. As a result, control of the vehicle could “become difficult or lost.”
Some 2016 Temsa TS35C coaches were assembled with defective front axle control arm bushings. “Hot crimping which connects tube ends with solid shafts of front axle control arm joint housings may crack and tube may separate from shaft. Control of vehicle may become difficult or lost.”
Due to incorrect wheel spacing, some 2015-2017 Temsa TS45 coaches had insufficient clearance between the rear twin tires, which could cause tire rubbing and premature tire failure. Wheels on all 13 affected coaches were replaced.
For certain 2017 J4500 coaches, MCI reported that, “Due to a multiplexing system program error, an audible or visible warning may not alert to a low air pressure condition in the vehicle’s primary service brake air reservoir system. Parking brakes could be applied automatically and without warning.”
On some 2013-2016 Temsa TS45 coaches, output pressure from an “inversion relay valve” could change and result in insufficient air pressure for the rear axle parking brake. The parking brake could become engaged while the vehicle is in motion.
Loss of power
Engine and transmission electrical relays on some 2008-2017 Volvo 9700 coaches were undersized and could fail, resulting in an engine shutdown and disabling the bus.
A ground cable on some 2016-2017 Volvo 9700 coaches may have been installed in the wrong location, causing an inadequate electrical contact that could cause a relay to fail, resulting in an engine shutdown and disabling the bus.
A possible bracket weld defect on Recaro Ergo-M operator’s seats led to a recall of a variety of MCI motorcoaches from the 2011 through 2016 models years; a Setra recall of some 2011-2012 coaches; and a Van Hool recall of several models manufactured for the 2011-2016 model years.
Some American Seating sliding passenger seats fitted to 2015-2016 Prevost X3-45 coaches developed fissure cracks at a mounting point and were replaced with redesigned components.
Kiel passenger seats in nine 2016 MCI J4500 motorcoaches may have been installed with one of four mounting bolts in an incorrect position.
Van Hool reported that the air brake release time on 48 motorcoaches — 2015 and 2016 TD925 and TDX models — did not meet federal specifications. Van Hool believed this did not pose a safety risk but NHTSA directed a recall.
Window mounting hardware on certain 2015 and 2016 MCI J4500 coaches with single-pane passenger windows may not have been properly installed, allowing bolts to become loose and potentially permit the upper mounting bracket to detach in the event of a collision or contact with the window.
A supplier reported that cracks or fractures could develop on certain windshield wiper arms fitted on 2016-2017 Prevost H3-45s. The cracks could cause the arms to detach. The wipers were replaced with modified castings.