Extensive Recall Issued for Isuzu and Chevrolet Trucks Due to Fire and Malfunction Risks

A significant safety recall has been initiated for thousands of Isuzu and Chevrolet trucks, including specific Chevrolet Low Cab Forward models, due to potential issues with chassis and cab harnesses. According to reports submitted to the National Highway Traffic Safety Administration (NHTSA), the defect could lead to a range of serious problems, including engine stalls, electronic parking brake malfunctions, and a heightened risk of fire. The recall affects a substantial number of vehicles manufactured between February 2024 and early 2026.

The issue stems from potential damage to the vehicle’s wiring harnesses, which may have occurred during the assembly process at the Fujisawa production facility. Investigations revealed that normal variations in harness structure and installation could lead to the harnesses contacting metal components within the vehicle. This contact can cause chafing, eventual damage to the harness, and in some cases, melting. While Isuzu Motors Limited, the manufacturer, has not received reports of accidents or injuries related to these harness failures, the potential consequences are severe.

The affected vehicles encompass a variety of Isuzu N-Series diesel trucks and Chevrolet Low Cab Forward diesel trucks, along with the electric Isuzu NRR EV. Specifically, the recall includes 2025-2027 Chevrolet Low Cab Forward 4500HD, 4500XD, and 5500XD models produced and shipped before a “Stop Ship” order was issued on March 25, 2026. Also included are 2025-2027 Isuzu NRR, NPR XD, and NPR HD diesel models, as well as 2025-2026 Isuzu NRR EV electric vehicles. A total of 14,028 vehicles are potentially involved in this recall.

The safety risks associated with a damaged harness are numerous and potentially critical. Beyond engine stalling, a compromised harness could lead to the electronic parking brake failing, the tail lamps not illuminating, or the Supplemental Restraint System (SRS) warning lights illuminating. Transmission shifting problems and malfunctions of the combination switch are also listed as potential outcomes. Crucially, damage to the 12-volt circuits within the harness can cause melting and charring, significantly increasing the risk of a vehicle fire. In some instances, warning lights on the dashboard may illuminate, or smoke and sparks could be visible on the left side of the vehicle behind the cab.

Isuzu’s investigation determined that the root cause was not a defect in the harnesses themselves, but rather their routing during installation. The newly designed cab introduced for the 2025 model year, which incorporated new harness locations and components like SRS elements, contributed to the complexity of the installation. Normal variations in worker positioning during assembly could allow harness branches to come into contact with metal parts, leading to the observed damage.

The remedy for this recall will involve inspecting both the chassis and cab harnesses for any signs of damage. If no damage to the wiring is found, the harnesses will be secured with additional fixing points to prevent future chafing. Should damage be present, the harness or harnesses will be repaired or replaced, depending on the extent of the physical harm. For the chassis harness, this will include adding a tie strap to the underside of the relay box and installing an edge protector at the frame-mounted bracket to prevent chaffing. For the cab harness, the SRS branches that might contact metal dash brackets will be taped to their connectors, rerouting them away from potential abrasion.

A “Stop Ship” order was enacted on March 25, 2026, for all affected Isuzu N-Series diesel and Chevrolet LCF vehicles at U.S. ports. Any vehicles shipped after this date will undergo the necessary repairs before being released to dealers. Owners of affected Chevrolet vehicles are advised to contact the GM Medium Duty Truck assistance line at 1-800-862-4389 for more information. Isuzu owners can reach out to Isuzu Customer Relations at 1-866-441-9638. Owners are instructed not to drive their vehicles and to park them outside until the necessary repairs are completed. The recall remedy is expected to be phased in, with dealer notification beginning in mid-April and owner notification and remedy availability commencing in late April and running through May 2026.

Article by Mel Anara, based upon information from Isuzu Motors Limited.

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