GILLIG Complaints

This complaint involves Gillig all-electric transit buses, model years 2024–2026, and a recurring failure of the electric air compressor supplying the air brake system. When the compressor fails, system air pressure drops, resulting in automatic application of the brakes. Unlike a conventional combustion-engine drivetrain, the all-electric drivetrain can continue producing sufficient torque to allow the driver to power through the automatically applied brakes, particularly when the low-air condition occurs while the bus is in motion. This condition has resulted in overheated brakes, damaged axle assemblies, and, most seriously, a wheel-end fire. Fortunately, the fire was extinguished when the bus returned to the maintenance facility. This appears to be a recurring condition affecting multiple buses rather than an isolated component failure. To my knowledge, Gillig is aware of the issue and has progressed through multiple versions of the electric air compressor, reportedly now at approximately a fourth-generation design, yet the safety issue has not been resolved. The failure identified in this complaint was reported to Gillig. Gillig subsequently provided Montgomery County with a seven-page diagnostic procedure that must be completed before warranty action or other corrective measures are considered. Given the recurring failures and the potential consequences, including brake overheating, axle damage, and fire, I believe this condition warrants NHTSA review as a potential safety defect. I respectfully request that NHTSA's Office of Defects Investigation evaluate this matter and consider an on-site inspection. The failure condition and affected buses can be demonstrated and documented at our maintenance facility. I believe an on-site evaluation would assist NHTSA in determining whether this represents a systemic safety defect and whether corrective action, including potential recall action, is warranted. Fleet Contact - [email protected]

We have approximately 495 buses that we found out can be started even though the battery disconnect switch is in the "disconnected" position. It will start and run for several minutes until the super capacitor is drained. This is hazardous to maintenance personnel who disconnect the batteries to work on the vehicle, then someone else may start it while that other person is in a dangerous position in the engine compartment.

THESE ARE THE CURRENT PRODUCTION 2021 ALL TYPES OF THEIR BUSES WITH THE ZF ELECTRIC STEERING COLUMNS. THEY FAIL ELECTRONICALLY AND MECHANICALLY. THE ELECTRONICS FAIL AND LOCK OUT THE ELECTRIC ASSIST AND THE STEERING WHEELS ARE BINDING CREATING A BUS THAT IS HARD TO STEER AND REQUIRING ENGINEERING INVOLVEMENT TO GET OPERATIONAL. NO ONE HAS BEEN A GREAT ASSISTANCE CAUSING THE BUSES TO BE PARKED AND OUT OF SERVICE.

I DRIVE BUSES FOR DISNEY WORLD AND THEY HAVE JUST GOT SOME NEW BUSES WITH NEW SEATS AND TWO PART SEAT BELTS. THE WAY THE LAP BELT AND SHOULDER BELT HOOK TOGETHER CAUSE THEM TO TWIST WHICH ALLOWS THE SHOULDER BELT TO JAM IN THE RETURN GUIDE NOT ALLOWING THE BELT TO FULLY RETRACT AND HOLD PROPERLY.I HAVE BEEN WRITTEN UP FOR NOT WEARING MY BELT PROPERLY BUT THIS IS A BELT ISSUE AND A MAJOR SAFETY CONCERN IF THE BELT WILL NOT FULLY RETRACT IT WILL NOT FULLY OPERATE IN A COLLISION. I HAVE SHOWED THIS TO A MANAGER AND ANOTHER WROTE ME UP FOR NOT WEARING IT PROPERLY.THIS NEVER OCCURS ON THE SEAT BELTS THAT ARE ONE PIECE AND CAN NOT TWIST. *TR

MICHELIN 305/85R22.5 XZU3 (J) SAME FAILURES THAT CAUSED THE VOLUNTARY RECALL OF 2012. ALL REMAINING PRODUCTION DATES AFTER THE RECALL (2011-WEEK 45 AND FORWARD). BEAD PLY SEPARATION AFTER 100,000 MILES. TIRES ARE BLOWING OUT FROM THE BEAD ON BUSES. MICHELIN REPRESENTATIVES HAVE ACKNOWLEDGED THAT THERE IS A PROBLEM AND INSTRUCTED US TO REMOVE ALL 2011 (POST RECALL) /2012 / 2013 TIRES FROM FLEET. THIS IS DEFINITELY A SAFETY ISSUE.

WE ARE A PUBLIC TRANSIT AGENCY IN VANCOUVER, WASHINGTON. OVER THE COURSE OF THE LAST 15 MONTHS WE HAVE HAD ROUGHLY 100 SIDEWALL BLOWOUTS OF MICHELIN XZU2 AND XZU3 TIRES. THE DATA ENTERED IS FROM ONE EVENT AND IS VERY INDICATIVE OF THE VAST MAJORITY OF THESE BLOWOUTS. ADDITIONAL INFORMATION AVAILABLE UPON REQUEST. *TR

ANN ARBOR TRANSIT PURCHASED 19 NEW 2003 GILLIG (800.735.1500) LOW FLOOR 40'&35' TRANSIT BUSES, DELIVERED OCTOBER 2003. IMMEDIATELY, ANN ARBOR TRANSIT EXPERIENCED BOTH FRONT EXTERIOR TURN SIGNAL FAILURES AFFECTING ALL 19 NEW BUSES. THE FAILURES INCLUDE BURNT OUT BULBS, LOOSE BULB SOCKET METAL CONTACTS, LAMP SOCKET WIRING HARNESS FALLING OFF. ANN ARBOR TRANSIT HAS FILED OVER FORTY WARRANTY CLAIMS WITHIN THE ONE YEAR PERIOD ONLY TO BE REJECTED. ANN ARBOR TRANSIT HAS SPOKEN TO GILLIG'S SERVICE MANAGER ONLY TO BE TOLD THAT WE ARE THE ONLY CUSTOMERS WITH THIS PROBLEM. GILLIG HAS SUPPLIED A NEW WIRING HARNESS TO CONSIDER, BUT THE NEW HARNESS WAS REJECTED BECAUSE IT WAS IDENTICAL TO THE EXISTING. GILLIG CLAIMS TO BE WILLING TO HELP, BUT DOES NOTHING. CURRENTLY, ALL 19 BUSES SHOULD BE CONSIDERED A SAFETY HAZARD DUE TO THE VERY UNRELIABLE FRONT TURN SIGNAL PERFORMANCE. ANN ARBOR TRANSIT OPERATES ABOUT 90 LARGE BUSES DAILY AND IS EXPECTED TO PROVIDE SAFE, RELIABLE, CLEAN BUSES TO ALL OF OUR 4 MILLION YEARLY CUSTOMERS, PLEASE HELP! *NM

THE REAR SUSPENSION FAILED. THE WELD LET LOOSE WERE THE SUSPENSION FRAME ATTACHES.