Recall 15V540 affects 696 2012-2015 Spartan Metrostar and Gladiator emergency vehicles for cracking front splay rails. Repair is free at any franchised Spartan dealer.
Spartan is recalling 696 2012-2015 Metrostar and Gladiator emergency vehicles because the front splay rails can crack. If the rails separate, the cab can collapse while it is being raised, increasing injury risk to people nearby; Spartan dealers will complete the recall repair free of charge.
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What's wrong?
The front splay rails on 2012-2015 Spartan Metrostar and Gladiator emergency vehicles are structural frame members at the front of the chassis cab. They help carry and brace the cab structure, including vehicles completed with a 10 inch or greater raised roof and a medium four door or longer cab. The rails are supposed to keep that front structure solid under normal road loads.
On the recalled vehicles, the weld area in the splay rail did not get enough weld penetration. That means the weld did not fuse deeply enough into the parent metal. Stress then concentrates at that weak area, and cracks form in the rail material. Spartan's remedy uses replacement splay rails whose welds were inspected by ultrasound to confirm proper penetration.
There is no warning sign before failure. The source problem is cracking in a structural rail, so an owner or operator should not rely on noises, warning lights, or visible symptoms before asking a Spartan dealer to inspect and repair an included vehicle.
Who's affected?
Spans the Metrostar and Gladiator chassis across the 2012-2015 model years, all tied to the same body or structural component.
| 2013 Spartan Metrostar | body or structural component |
|---|---|
| 2013 Spartan Gladiator | body or structural component |
| 2015 Spartan Metrostar | body or structural component |
| 2014 Spartan Metrostar | body or structural component |
| 2015 Spartan Gladiator | body or structural component |
| 2014 Spartan Gladiator | body or structural component |
| 2012 Spartan Metrostar | body or structural component |
| 2012 Spartan Gladiator | body or structural component |
| Units affected | 696 |
| Field incidents | NHTSA has logged 1 field incident to date. |
The model year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific truck is included.
What's the safety risk?
Cracked front splay rails can separate and let the cab collapse while it is being raised, increasing injury risk for people nearby. Cracks can occur without warning, so keep people clear during cab-raising work and schedule the repair soon. Repair is free at any franchised Spartan dealer.
What should I do?
- Check your VIN to confirm your 2012-2015 Spartan Metrostar or Gladiator is included in this recall.
- Contact a franchised Spartan dealer to schedule the free front splay-rail replacement that fixes the cracking frame rails under the cab.
- Bring the recall notice if Spartan mailed one. If not, reference recall number 15V540 when you call.
- Avoid raising the cab until the splay-rail replacement is complete.
- Call Spartan customer service at 1-517-543-6400 with questions about scheduling or repair status.
What happens at the repair
At the dealer, a Spartan technician replaces the splay rails with new splay rails that have certified welds. The replacement parts and labor are free under the recall. If you already paid for a related splay rail repair before the recall work was completed, Spartan's general reimbursement plan covers documented out-of-pocket costs. Bring repair invoices, proof of payment, and any related service paperwork to the service desk so the dealer can explain the claim process.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 25, 2015 | NHTSA published the recall |
|---|---|
| October 27, 2016 | Dealer notification began |
| October 27, 2016 | Dealer notification ended |
| October 27, 2016 | Interim owner notification (was planned for this date) |
| October 31, 2016 | Owner notification mailed |
Frequently asked questions
What is recall 15V540?
Recall 15V540 covers 696 2012-2015 Spartan Metrostar and Gladiator emergency vehicles with front splay rails that can crack. If the rails separate while the cab is raised, the cab can collapse and increase injury risk to people nearby. Spartan will replace the splay rails for free.
What should I do if my 2012-2015 Spartan Metrostar or Gladiator is on this recall?
Check your VIN to confirm your specific emergency vehicle is included in recall 15V540. If it is, contact a Spartan dealer or Spartan customer service at 1-517-543-6400 to arrange the splay-rail replacement. Reference Spartan recall number 15019 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and Spartan's remedy states that the splay rails will be replaced free of charge. Parts and labor are covered through Spartan's recall process.
What is the safety risk in recall 15V540?
The risk is injury to people near the vehicle when the cab is being raised. If the front splay rails crack and separate, the cab can collapse during that raised-cab service position. The repair replaces the rails with new splay rails with certified welds.
What if I bought my Spartan Metrostar or Gladiator used?
The free recall repair still applies. Federal recall law follows the vehicle, not the original owner. Check your VIN to confirm whether your specific 2012-2015 Spartan Metrostar or Gladiator is included, then contact a Spartan dealer or Spartan customer service with recall number 15019.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/15V540000 |
|---|---|
| Spartan customer service | 1-517-543-6400 |
| NHTSA recall # | 15V540 |
| NHTSA recall # (full) | 15V540000 |
Source documents
-
Download Misc. Document (PDF) - Download Recall Document (PDF) (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →