Damaged Brake Line May Leak Brake Fluid

Affected vehicles (3)

Component / system

Defect

Halcore Group, Inc. (Halcore) is recalling certain 2023-2024 Horton emergency vehicles built on Ford F450, F550, and F600 chassis. The left rear steel brake line can contact the strut mount when the rear suspension is lowered, damaging the brake line.

Risk / consequence

A damaged line can leak brake fluid, causing a loss of brakes and increasing the risk of a crash.

Remedy

Dealers will replace and secure the brake line as necessary, free of charge. Owner notification letters were mailed April 17, 2024. Owners may contact Halcore customer service at 1-800-447-0343.

Chronology of events

1. Jan 24, 2024

   01/24/24- While a vehicle was on a lift after standard end of production road test, an associate noticed a brake line making contact with LS parts. 01/24- Parts were inspected to validate the correct LS kit was installed. It was determined a MY22 F-series LS kit was installed on a MY23-24 chassis. MY23-24 requires a new part to accommodate changes to the parking brake on MY23-24 units, which the MY22 kit didn’t have. 01/24- MY23-24 LS kits were inspected to see if the required parts are included, it was determined MY23-24 LS kits have correct parts. 01/24- Stop ship issued on non-delivered units at HEV. Immediate containment to verify effected units at plant. 01/25 AM- HEV leadership reached out to REV Compliance to notify them of the issue. 01/25- Issue raised to other REV ambulance BUs. It was determined that AEV may also be affected. 01/25- Quality stand down held with chassis team to discuss the issue and ensure awareness/training. 01/25- Investigation into delivered units with incorrect parts installed is initiated. Total population found to be 31 at Horton and 4 at AEV, based on install dates. 01/25- Verification of units starts, working from delivery back to cell 1. Repairs started. 01/26- HEV leadership meets to discuss the issue, response, and next steps. Drafting of DIR begins. 02/16- REV Leadership approved the DIR and a decision file a recall was made.

Notification schedule

Dealer notification

FEB 19, 2024 - MAR 19, 2024

Owner notification

MAR 19, 2024 - APR 19, 2024

Documents (14)