2019 Proterra Catalyst problems

What is wrong

Phoenix Motorcars (Phoenix) is recalling certain 2019-2021 800V Catalyst and 2020-2022 ZX5 transit buses. The vehicle controller software may allow the electrical circuit for the radiator fan to overheat.

Risk

Electrical circuits that overheat increase the risk of a fire.

Remedy

Dealers will update the vehicle software, free of charge. Owner notification letters were mailed October 15, 2024. Owners may contact Phoenix customer service at 1‑909‑987‑0815.

Recall number 24V655000 · Recall details

What is wrong

Proterra Operating Company, Inc. (Proterra) is recalling certain 2019-2022 40' and 35' Catalyst 800V transit buses equipped with ProDrive 1.0, and 40' and 35' ZX5 800V transit buses equipped with ProDrive 1.0. A transistor inside the inverter may overheat and fail, which can result in a loss of power steering and drive power.

Risk

A loss of power steering and/or drive power increases the risk of a crash.

Remedy

Dealers will replace the inverter, free of charge. Owner notification letters were mailed December 16, 2023. Owners may contact Proterra customer service at 1‑864‑438‑0000.

Recall number 23V697000 · Recall details

What is wrong

Proterra Operation Company, Inc. (Proterra) is recalling certain 2017-2019 Catalyst transit buses. One or more battery packs may allow liquid to leak into and accumulate in the battery pack enclosure.

Risk

The accumulation of liquid inside the battery pack enclosure increases the risk of a fire.

Remedy

Proterra will update software, inspect, and replace the battery pack, free of charge. Owner letters were mailed November 6, 2023. Owners may contact Proterra's customer service at 1‑864‑438‑0000.

Recall number 22V887000 · Recall details

What is wrong

Proterra, Inc. (Proterra) is recalling certain 2017-2019 35 foot Catalyst E2, 2017-2019 40 foot E2, 2020-2021 35 foot RR, 2019-2020 40 foot RR, 2019-2022 40 foot ZX5, and 2020-2022 35 foot ZX5 buses. The plexus adhesive between the torque limiter plate and the bus body may be insufficient, causing the bolts that secure the steering gearbox to loosen.

Risk

A loose steering gearbox can cause a loss of steering control, increasing the risk of a crash.

Remedy

Dealers will install a mechanical fastener and new bolts on the steering gearbox, and install a new torque plate, as necessary, free of charge. Owner notification letters were mailed October 7, 2022. Owners may contact Proterra's customer service at 1‑864‑438‑0000.

Recall number 22V114000 · Recall details

What is wrong

Proterra, Inc. (Proterra) is recalling certain 2019-2020 Catalyst 40 foot buses. A software defect in the body controller that operates the door motor may allow the rear door to open unexpectedly.

Risk

The rear door may open without the driver's awareness, increasing the risk of injury.

Remedy

Proterra will notify owners, and dealers will update the software, free of charge. Owner notification letters were mailed on June 11, 2021. Owners may contact Proterra customer service at 1‑864‑438‑0000.

Recall number 21V268000 · Recall details

What is wrong

Proterra Inc. (Proterra) is recalling certain 2018-2020 35 foot and 40 foot Catalyst buses. Lack of plexus adhesive between the torque plate and the vehicle chassis may cause the bolts securing the steering gear box to loosen.

Risk

An unsecured steering gear box could cause the driver to lose the ability to steer the vehicle, increasing the risk of crash or injury.

Remedy

Proterra will notify owners, and dealers will inspect the steering gear mounting bolts and the plexus adhesive layer between the torque plate and the chassis. If the plexus adhesive layer is missing or insufficient, the components will be repaired, free of charge. The recall began December 10, 2020. Owners may contact Proterra customer service at 1‑864‑438‑0000. Proterra's number for this recall is SC-20-154.

Recall number 20V664000 · Recall details

What is wrong

Proterra Inc. (Proterra) is recalling certain 2019-2020 Battery-Electric 40' Catalyst and 2020 Battery-Electric 35' Catalyst buses. The power steering hose located at the pump and reservoir may leak and sweat fluid through the hose.

Risk

A power steering fluid leak can increase the risk of a crash.

Remedy

Proterra will notify owners, and dealers will inspect and replace the power steering hose, free of charge. The recall began October 6, 2020. Owners may contact Proterra customer service at 1‑864‑438‑0000. Proterra's number for this recall is SC-20-141.

Recall number 20V621000 · Recall details

What is wrong

Proterra, Inc. (Proterra) is recalling certain 2019 Catalyst buses. A body controller software update may have disabled the audible and visible warnings that notifies the operator that the brake interlock could be engaged.

Risk

If the vehicle does warn the driver that the brake interlock is engaged, the rear brakes may overheat, increasing the risk of a fire or crash.

Remedy

Proterra will notify owners, and dealers will update the body controller software, free of charge. The recall began January 16, 2020. Owners may contact Proterra customer service at 1‑864‑438‑0000.

Recall number 19V871000 · Recall details

What is wrong

Proterra, Inc. (Proterra) is recalling certain 2018-2019 Catalyst buses equipped with a certain batch of glass roof hatches. Temperature and vibration stresses may cause the tempered glass roof hatch to shatter.

Risk

If the tempered glass roof hatch shatters, glass fragments may fall onto passengers, increasing the risk of an injury.

Remedy

Proterra will notify owners, and the glass hatch manufacturer will provide replacement hatch lids, free of charge. The recall began August 13, 2019. Owners may contact Proterra at 1‑864‑438‑0000. Proterra's number for this recall is SC-19-79.

Recall number 19V460000 · Recall details

In November 2022, Proterra Operating Company, Inc. (Proterra) filed a safety recall (the federal safety agency recall 22V887) covering nineteen 2017-2019 Proterra Catalyst transit buses to address the potential of liquid accumulation in the 400-volt battery packs, increasing the risk of a fire. On December 16, 2022, Proterra mailed an interim owner notification letter stating that Proterra would physically inspect and analyze each recalled battery pack.In October 2023, Proterra amended their filing to now cover 300 vehicles, with a final remedy plan of updating the battery monitoring software. According to the final remedy documents from Proterra, should liquid be detected within the battery pack, the updated software would illuminate a warning light in the driver's dash display, prevent the batteries from being charged, and reduce the maximum speed of the buses.As of the most recent recall completion rate report, 109 of the 300 buses (36.3%) have received the software update. In August 2023, Proterra declared bankruptcy, with its the three major business areas going to three separate companies.Phoenix Motorcars assumed liability for recall 22V887. On June 5, 2025, a fire occurred at the Southeastern Pennsylvania Transportation Authority (SEPTA) decommissioning lot.Local officials stated that the fire initiated in a battery pack of one of the Proterra buses. The Office of Defects Investigation (ODI) is opening this Recall Query (RQ) to evaluate the remedy effectiveness of recall 22V887 and to further understand the effects of nearly two-thirds of the affected population having not yet received the recall remedy.

RQ25001