2020 Gillig Low Floor problems, complaints & recalls

Defect: Gillig, LLC (Gillig) is recalling certain 2019-2024 Low Floor transit buses. The rivet-nut fasteners that secure the TFT flat panel display monitor to the bus ceiling may fail, causing the monitor to detach and fall.

Risk: A monitor that detaches and falls from the ceiling increases the risk of injury.

Fix: Gillig will replace the rivet-nut fasteners, free of charge. Owner notification letters were mailed March 18, 2025. Owners may contact Gillig customer service at 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2019-2023 Low Floor transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.

Risk: A sudden loss of drive power can increase the risk of a crash. Additionally, a disabled bus may require an evacuation procedure in an uncontrolled traffic situation, increasing the risk of injury to passengers.

Fix: Gillig will work with the equipment manufacturer, Allison Transmission Inc., to inspect and tighten the transmission yoke bolts, as necessary, free of charge. Owner notification letters were mailed December 11, 2023. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2019-2022 Low Floor vehicles equipped with Cummins BP74E battery packs. The battery packs may develop a coolant leak internally, causing the battery pack to short circuit.

Risk: A battery short circuit increases the risk of a fire.

Fix: Gillig will tighten the coolant fittings and replace the coolant, free of charge. Owner notification were mailed on August 16, 2022. Owners may contact Gillig's customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2019-2022 Low Floor electric transit buses. The EV resolver cable connector may experience a loss of electrical connectivity, unexpectedly switching from Drive to Neutral with no warning.

Risk: An unexpected switch to neutral can cause a loss of vehicle propulsion and increase the risk of a crash.

Fix: Dealers will install a redesigned resolver cable with extended length and a new support bracket, free of charge. Owner notification letters were mailed on August 3, 2022. Owners may contact Gillig's customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2014-2021 Low Floor transit buses. The rear-mounted ultracapacitors may allow the engine to be started when the master battery disconnect switch is in the "OFF" position.

Risk: The engine may be started unexpectedly, increasing the risk of injury to anyone nearby the engine compartment during maintenance operations.

Fix: Dealers will update the software for the buses equipped with the Vanner Ultracapacitor system, and conduct a hard rewire for the buses equipped with the KBI system, free of charge. Owner notification letters were mailed on June 22, 2022. Owners may contact Gillig's customer service at 1-510-264-5073 for 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2020-2021 Low Floor vehicles equipped with Cummins L9 Diesel Engines that have remote Stage 2 fuel filters and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and the remote fuel filter head.

Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.

Fix: Cummins will replace the fuel hoses, free of charge. Owners may contact Gillig's customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2020-2021 Low Floor vehicles equipped with Cummins L9 Diesel Engines. The engine calibration software's management of the injection of Diesel Exhaust Fluid can allow excessive ammonia into the tailpipe exhaust.

Risk: Exposure to high levels of ammonia can increase the risk of injury.

Fix: Cummins will recalibrate the engine, free of charge. Owners may contact Gillig's customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2020-2021 Low Floor Diesel, CNG, and Battery Electric buses. The rear axle may come out of alignment during operation.

Risk: An improperly aligned rear axle may cause a loss of vehicle control, increasing the risk of a crash.

Fix: Gillig will install a new locknut, free of charge. Owner notification letters were mailed on July 19, 2021. Owners may contact Gillig's customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC. (Gillig) is recalling certain 2017-2020 Low Floor vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.

Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.

Fix: Gillig will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on August 27, 2021. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC (Gillig) is recalling certain 2020-2021 29, 35, 40-foot Low Floor and BRT buses powered by Compressed Natural Gas (CNG). The overlap between the curb side and street side roof doors is insufficient and may allow the street side door to accidentally open.

Risk: An open door may strike another vehicle or structure, increasing the risk of a crash.

Fix: Dealers will install a new locking plate, overlap bracket, and mounting hardware, free of charge. Owner notification letters were mailed on May 14, 2021. Owner may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.

Defect: Gillig, LLC. (Gillig) is recalling certain 2013-2020 hybrid and all-electric Low Floor buses equipped with a steering system that uses a high-voltage electric motor and hydraulic pump assembly to provide power steering assist. The shaft coupling between the motor and pump may fail and cause a loss of hydraulic power steering assist.

Risk: A loss of power steering assist may increase the risk of crash.

Fix: Gillig will notify owners, and dealers will replace the motor-pump assemblies, free of charge. The recall began August 13, 2020. Owners may contact Gillig customer service at 1-800-735-1500.

Defect: Gillig LLC (Gillig) is recalling certain 2018-2020 Low Floor buses. The rear suspension lower control rods may experience fatigue failure due to stiffened end bushings.

Risk: If the rear suspension lower control rod fails, the bus may have reduced handling and stability, increasing the risk of a crash.

Fix: Gillig will notify owners and provide them with new lower control rods with different bushings, free of charge. This recall began June 26, 2020. Owners may contact Gillig customer service at 1-800-735-1500.

Defect: Gillig LLC (Gillig) is recalling certain 2018-2020 Low Floor transit buses powered by compressed natural gas (CNG). The thermally activated pressure relief device (PRD) installed on the CNG fuel system may not vent the system when exposed to heat, potentially resulting in the system rupturing.

Risk: If the fuel system ruptures from exposure to heat, there may be an increased risk of injury.

Fix: Gillig will work with Agility to notify customers and replace the PRDs, free of charge. The recall began May 15, 2020. Owners may contact Agility customer service at 1-949-267-7745 or Gillig customer service at 1-800-735-1500.

Defect: Gillig LLC (Gillig) is recalling certain 2012-2020 Low Floor buses. The circuit breaker ratings on the DEF Line Heater circuit and the Aftertreatment-Ignition circuit may be higher than the rating for the wire and connector.

Risk: With the improper circuit breaker rating, an electrical short in either of these circuits may increase the risk of a fire.

Fix: Gillig will notify owners, and dealers will replace the circuit breakers, free of charge. The recall began April 24, 2020. Owners may contact Gillig customer service at 1-510-264-5073 or 1-800-735-1500.