Defective Latch may Prevent Door from Opening

Affected vehicles (3)

Component / system

Defect

Marion Body Works Inc. (Marion Body Works) is recalling certain 2024-2025 Spartan Fire FC-94, Gladiator, and Metrostar vehicles. The actuator lever arm in the cab door latch may bind or become wedged, preventing the door from opening.

Risk / consequence

A door that cannot be opened may trap occupants inside the vehicle, increasing the risk of injury.

Remedy

Dealers will inspect and replace the door latches as necessary, free of charge. Owner notification letters were mailed November 14, 2025. Owners may contact Marion Body Works customer service at 1-715-754-5261.

Chronology of events

1. May 1, 2025

   May 1, 2025 – Spartan Fire Chassis (Spartan) received claim of a cab door latch logic issue.

2. May 5, 2025

   May 5, 2025 – Spartan notified supplier of issue.

3. May 19, 2025

   May 19, 2025 – Spartan received parts from field and started internal investigation with Engineering and Supplier.

4. Jun 19, 2025

   June 19, 2025 – Spartan shipped returned parts back to Supplier. June 24, 2025 – Supplier received parts from Spartan. July 1 – August 8, 2025 – Supplier started corrective action request to determine root cause, started cycle testing on door frames, and contained internal inventory. Spartan opened PSR, issued SCAR with Supplier, reviewed chassis cab production inventory and identified potential population.

5. Aug 13, 2025

   August 13, 2025 – Supplier was onsite at Spartan Fire Chassis production to review application of the product, confirmation of the test results, and product inspection procedures.

6. Aug 20, 2025

   August 20, 2025 – Spartan conducted risk assessment and stop ship issued.

7. Aug 21, 2025

   August 21, 2025 – Spartan escalated the issue to REV Group Management.

8. Aug 29, 2025

   August 29, 2025 – REV’s senior leadership approved a voluntary recall for this issue.

9. Sep 5, 2025

   September 5, 2025 - Spartan determined final population.

Notification schedule

Dealer notification

Nov 10, 2025 - Nov 14, 2025 No Dealers

Owner notification

Nov 10, 2025 - Nov 14, 2025 Phased Recall