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The National Highway Traffic Safety Administration (NHTSA) recalled 40 of Oshkosh Defense’s 2025 model year Next Generation Delivery Vehicles (NGDVs) last month.
The NGDV is the replacement for the U.S. Postal Service's Grumman Long Life Vehicles (LLVs), offered as both battery-electric and gas-powered variants.
Affected vehicles include 10 electric and 30 gas-powered trucks produced between March 28 and July 16, 2025.
Following two incidents where rear wheels separated from the axle hub in 2025, Oshkosh conducted an evaluation of the failed components. The automotive manufacturer found no evidence of material defects, but after reviewing manufacturing records determined one of the five hub fasteners was double torqued.
The NHTSA’s Part 573 Safety Recall Report states the improperly torqued hub fasteners may come loose over time and not provide enough clamp load, causing the brake rotor to separate from the rear axle hub which can then cause the wheel to separate.
A detached wheel can cause a loss of vehicle control or become a road hazard for other vehicles, increasing the risk of a crash.
Oshkosh submitted a Defect Information Report to the NHTSA Jan. 15.
The manufacturer updated its torque tool program to detect whether hub fasteners have been double torqued or not.
Vehicles produced after Jan. 14 have been subjected to this program to ensure the rear axle hub fasteners are properly fastened.
Oshkosh will replace and properly tighten the fasteners free of charge. All affected vehicles are covered by the new vehicle warranty.
Because Oshkosh sells the NGDV only to USPS and not through dealers, no dealer notification was provided. A letter was sent to USPS Jan. 30.
The NHTSA has issued multiple recalls for Oshkosh’s NGDV.
In Sept. 2024, USPS drivers reported the overhead display screen intermittently going blank, but returning after turning the truck off then on again. The screen displays information including a 360-degree view around the truck and is controlled by a head unit.
From Sept. to Nov., 2024, Oshkosh and its head unit supplier investigated conditions that would cause the screen to go blank and whether the 360-degree camera system impacted the rear-view image shown when the truck is placed in reverse.
If the screen cannot show a backup image, the vehicles do not comply with Federal Motor Vehicle Safety Standard (FMVSS) 111 - Rear Visibility.
Oshkosh and its supplier determined firmware and software issues caused the display screen to lock up. In Dec. 2024, NHTSA issued a recall for 144 NGDVs because of the potential to lose rearward visibility.
Oshkosh replaced the head units with new firmware on all 144 affected vehicles by March 2025 for free. But throughout that month, the company received four reports of the screens going blank on startup for NDGVs with the replacement head units.
The supplier informed Oshkosh that “process shortcomings” did not consistently allow for the firmware update to fully complete. If the firmware update was interrupted before fully completing, it can lead to intermittent blank rear-view camera display screens when the vehicle is placed into reverse.
In April 2025, NHTSA issued a recall for 216 NGDVs because of the potential to lose rearward visibility. Oshkosh ensured the head unit firmware was updated on all 216 affected vehicles - including replacing the head unit on those with incomplete updates - by July 2025.
In April 2024, Oshkosh received a report of the nut securing the windshield wiper arm to the motor shaft becoming loose. From Jan. to Feb. 2025, the manufacturer observed loose wiper arm nuts on three vehicles in a "post-assembly care area.”
Oshkosh determined if unrelated work required removing the wiper arm assembly, process steps were not present upon re-assembly to ensure the bolt was tightened properly.
In March 2025, NHTSA issued a recall for 169 NGDVs because of the potential for wiper arm failure, which could impact driver visibility and increase crash risk.
Oshkosh modified its post-assembly process to re-torque the bolt correctly, and bolts on all 169 affected vehicles were inspected and tightened by October 2025.
In May 2025, Oshkosh began noticing the airbag and rollover warning labels on sun visors wrinkling on NGDVs at its facility.
In June 2025, NHTSA issued a recall for 917 NGDVs because the air bag warning labels on the sun visor did not adhere properly and may fall off. If the warning labels fall off, the vehicles would violate FMVSS 208 - Occupant Crash Protection.
Oshkosh will replace the sun visor assembly and add an electric shock warning label free of charge. As of the 2025-Q4 quarterly report issued Feb. 2, the replacement was completed on 12 of the 917 NGDVs affected.
The NHTSA's mission is to save lives, prevent injuries, and reduce economic costs due to road traffic crashes, through education, research, safety standards, and enforcement.
Donald Halsing is the Founding Editorial Director of Work Safety 24/7. He was formerly the Associate Editor of Robotics 24/7.
Don's experience spans the supply chain, logistics, and construction industries, having worked in both warehouse operations and land surveying. He is also a professional wedding photographer with his fiancée Ashley.
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