Chrysler (FCA US, LLC): Safety Recalls in 1978

THE INVOLVED VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC BRAKE SYSTEMS". THIS REQUIRES THAT SCHOOL BUSES HAVE A BRAKE FLUID WARNING STATEMENT LOCATED ON OR WITHIN FOUR INCHES OF THE BRAKE FLUID RESERVOIR FILLER CAP.

THE WHEEL MOUNTING NUTS INSTALLED MAY BE INCORRECT DUE TO A SUPPLIER ERROR IN MIXING STANDARD THREAD NUTS WITH SPECIFIED METRIC THREAD NUTS PRIOR TO PLANT SHIPMENT. AS A RESULT, THE NUT THREADS MAY STRIP WHEN TIGHTENED TO THE SPECIFIED TORQUE LEVEL RANGE, WITH THE POTENTIAL FOR THE LOOSENING OF A ROAD WHEEL.

THE THROTTLE LINKAGE CONTROL SPRING MAY NOT CLOSE RAPIDLY WHEN THE ACCELERATOR PEDAL IS RELEASED. IF THE THROTTLE DOES NOT CLOSE AS RAPIDLY AS EXPECTED, THE VEHICLE WILL NOT DECELERATE PROPERLY. THIS FAILS TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO.124, "ACCELERATOR CONTROL SYSTEMS".

THE INVOLVED VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS". THE REQUIRED UNDERBODY SEAT REINFORCEMENTS MAY HAVE BEEN OMITTED DURING ASSEMBLY. WITHOUT THE REINFORCEMENTS, THE SEAT ASSEMBLIES MAY NOT BE ADEQUATELY SECURED TO THE VEHICLE STRUCTURE TO PREVENT SEAT DETACHMENT IN A VEHICLE CRASH SITUATION.

THE CLAMP BOLTS ON THE ADJUSTER TUBE THAT FASTENS THE CONNECTING ROD TO THE PITMAN ARM END ASSEMBLY MAY BE LOOSE. THESE LOOSE BOLTS COULD CAUSE SHIFTING OF THE STEERING WHEEL POSITION, RELATIVE TO THE STRAIGHT-AHEAD-FRONT WHEEL POSITION, AND LOSS OF STEERING.

THE MANUAL LOCK RELEASE LEVER ON THE SPLIT-BACK BENCH ASSEMBLIES MAY HAVE BEEN BENT DURING ASSEMBLY. THIS BENT CONDITION COULD PREVENT THE INERTIA SEAT LOCK ASSEMBLY FROM FUNCTIONING AUTOMATICALLY. AS A RESULT, THE FRONT SEAT BACK MAY NOT LOCK IN THE UPRIGHT POSITION IF THE CAR IS MOVING FORWARD AND BROUGHT TO AN ABRUPT STOP.

ON THE INVOLVED VEHICLES, THE FUEL FILTER INLET, OUTLET, AND VAPOR RETURN FUEL LINE HOSES MAY DETERIORATE IF CONTINUOUSLY EXPOSED TO UNDERHOOD TEMPERATURES GENERATED DURING VEHICLE OPERATION. IF HOSES FAIL, FUEL LEAKAGE COULD OCCUR.

DUE TO IMPROPER MATERIAL CONSTRUCTION THE HYDRO-BOOST FLUID RETURN HOSE MAY NOT BE CAPABLE OF WITHSTANDING THE TEMPERATURES AND/OR PRESSURES EXPERIENCED WITH THE HYDRO-BOOST SYSTEM. ALSO, THE HYDRO-BOOST FLUID HIGH PRESSURE HOSE ASSEMBLY MAY HAVE BEEN MISLOCATED, ALLOWING THE ASSEMBLY TO CONTACT THE FRAME SIDE RAIL. ABRASION RESULTING FROM CONTINUED CONTACT ALONG WITH IMPROPER MATERIAL CONSTRUCTION MAY CAUSE PRESSURE HOSE FAILURE. EITHER OF THESE CONDITIONS MAY CAUSE HYDRO-BOOST FLUID LEAKAGE, RESULTING IN THE LOSS OF POWER ASSIST FOR THE STEERING AND BRAKING SYSTEMS. COMPLETE LOSS OF STEERING OR BRAKING WILL NOT OCCUR SINCE BOTH SYSTEMS WOULD REVERT TO MANUAL OPERATION.

HUB SEPARATION, DUE TO CRACKS BETWEEN THE INNER AND OUTER BEARING OF THE HUB, CAN OCCUR WHICH WILL LEAD TO HUB FAILURE. WHEN FAILURE OCCURS, THE SEPARATED HUB IS RETAINED ON THE AXLE SPINDLE BY THE WHEEL BEARING ADJUSTING NUTS, AND CAN RESULT IN TWO POSSIBLE CONDITIONS: 1) GENERATION OF EXCESSIVE HEAT RESULTING FROM THE BRAKE LINING CONTACTING THE DRUM CAUSING A BLOWN TIRE AND/OR FIRE, AND 2) PROGRESSIVE DAMAGE TO THE HUB WHICH WOULD ALLOW THE SEPARATED HUB WITH THE WHEEL AND TIRE TO BECOME DISENGAGED FROM THE VEHICLE IN AN UNCONTROLLED MANNER.

THE ENGINE COMPARTMENT FUEL PUMP TO CARBURETOR CONFIGURATION MAY BE INCORRECT DUE TO THE MISUSE OF COMPONENTS AND ROUTINGS. AS A RESULT, THE FUEL PUMP COULD DISENGAGE FROM THE CARBURETOR, CAUSING FUEL LEAKAGE.

IMPROPER ROUTING OF THE "HYDROBOOST" HYDRAULIC SYSTEM HIGH PRESSURE HOSE ASSEMBLY COULD ALLOW A TUBULAR SECTION TO CONTACT THE FRAME SIDE RAIL. ABRASION FROM THE CONTACT COULD RESULT, CAUSING A LEAK IN THE HOSE ASSEMBLY.

THE PRESENT POSITION OF THE FUEL HOSE MAY ALLOW IT TO CHAFE AGAINST THE AIR CONDITIONING SUCTION HOSE. EXCESSIVE CHAFING COULD RESULT IN FUEL LEAKAGE.

POOR CLAMPING OF THE CARBURETOR FUEL INLET HOSE TO THE INLET TUBE AND CARBURETOR NIPPLE COULD ALLOW FUEL LEAKAGE TO OCCUR.

THE RIVET ATTACHMENTS FOR THE FRONT SUSPENSION CONTROL ARM TO BALL JOINT MAY FAIL, ESPECIALLY UNDER IMPACT LOAD CIRCUMSTANCES.

POSSIBLE FATIGUE FAILURE CAN OCCUR IN THE FRAME SUPPORT PLATES (FRONT SUSPENSION PIVOT BAR SUPPORT PLATE) THAT CONNECTS A PORTION OF THE FRONT SUSPENSION TO THE VEHICLE FRAME ON THE INVOLVED VEHICLES.

THE INVOLVED VEHICLES DO NOT CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES", IN THAT THEY DO NOT HAVE THE CAPABILITY OF FITTING CERTAIN ADULT PASSENGERS WHEN THE SEAT IS IN THE FULL FORWARD POSITION.

THE HIGH PRESSURE POWER STEERING HOSE MAY HAVE BEEN ROUTED TOO CLOSE TO THE EXHAUST MANIFOLD. AS A RESULT, THE HEAT FROM THE MANIFOLD COULD DAMAGE THE HOSE.

VEHICLES WERE BUILT WITH WIRE CONNECTORS THAT FAIL TO ALLOW THE CURRENT FLOW NEEDED TO SUPPORT THE ELECTRONIC CONTROL OF THE ENGINE IGNITION.

THE ELECTRONIC IGNITION SYSTEM SENSOR CIRCUIT CONTAINS A TWO-WIRE CONNECTOR WHICH COULD CAUSE DIFFICULTY IN THE ENGINE IGNITION. THIS DIFFICULTY MAY BE CAUSED BY MECHANICAL OR CHEMICAL ACTIONS AT THE CONNECTOR.

THE COUPLING WHICH ATTACHES THE INTERMEDIATE STEERING SHAFT TO THE STEERING GEAR MAY HAVE OVERSIZED SERRATIONS WHICH COULD PREVENT THE COUPLING FROM BEING PROPERLY TIGHTENED IN THE STEERING GEAR SHAFT WHEN THE STEERING WHEEL IS TURNED. THIS MAY ALSO CAUSE FREE PLAY IN THE STEERING WHEEL.

THE STEERING LINKAGE TIE ROD ENDS AND DRAG LINK BALL JOINTS ON THE INVOLVED VEHICLES MAY NOT HAVE BEEN LUBRICATED.

THE INVOLVED VEHICLES MAY HAVE BEEN BUILT WITH THE TRANSMISSION ADAPTER PLATE SEAL IMPROPERLY SEATED. THIS CONDITION COULD ALLOW A GRADUAL TRANSFER OF LUBRICANT FROM THE TRANSMISSION TO THE TRANSFER CASE.

AN INTERMEDIATE STEERING SHAFT CONTAINING A MISMATCHED POT COUPLING ASSEMBLY MAY HAVE BEEN INSTALLED ON THE INVOLVED VEHICLES. THIS COUPLING MAY HAVE AN OVERSIZED SERRATION DIAMETER. AN OVERSIZED SERRATION COULD PREVENT THE COUPLING FROM ADEQUATELY TIGHTENING ONTO THE GEAR OR SHAFT SPLINES.

THE FUEL TANKS ON THE INVOLVED VEHICLES MAY EXHIBIT FUEL LEAKAGE WHEN COMPLETELY FILLED. THIS CONDITION WAS CAUSED BY THE REAR FLOOR CARPET FASTENERS PENETRATING THE TOP OF THE FUEL TANK.

WHEN THE ACCELERATOR PEDAL ON THE INVOLVED VEHICLES IS DEPRESSED AND THE ACCELERATOR PUMP IS ACTIVATED, A DISTORTED ACCELERATOR PUMP SEAL IN THE CARBURETOR MAY PREVENT THE PUMP FROM DELIVERING THE PROPER AMOUNT OF FUEL.