FREIGHTLINER LLC: Safety Recalls in 2004

ON CERTAIN VEHICLES, THERE IS A DEFECT IN THE INTERAXLE DRIVELINE YOKES. THE BOLT HOLES LOCATED ON THE EARWORK OF THE MALE SHAFT YOKES WERE MANUFACTURED WITH AN OVERSIZED MINOR THREAD DIAMETER.

ON CERTAIN TRUCKS, THE BRAKE PEDAL PUSHROD WAS NOT TIGHTENED PROPERLY DURING ASSEMBLY.

ON CERTAIN TRUCKS EQUIPPED WITH MICHELIN 365/85 R20 TIRES, THE TIRES MAY NOT BE COMPATIBLE WITH THE MAXIMUM LOAD AND MAXIMUM SPEED RATINGS.

ON CERTAIN TRUCKS EQUIPPED WITH LIQUID NATURAL GAS (LNG) STYLE TANKS, NEITHER THE PRIMARY NOR THE SECONDARY RELIEF VALVES HAVE OPENED TO RELIEVE TANK PRESSURE UNDER CERTAIN CONDITIONS. SPECIFICALLY, THE INTRODUCTION OF WATER INTO THE DISCHARGE SIDE OF BOTH OF THESE VALVES SIMULTANEOUSLY AND SUBSEQUENT FREEZING IN SERVICE CAN RENDER THE VALVES TEMPORARILY INOPERATIVE.

ON CERTAIN TRUCKS, THE STEERING GEAR BOLTS MAY BECOME LOOSE.

CERTAIN 1995 AND 1996 MY THOMAS BUILT SCHOOL BUSES BUILT BETWEEN JANUARY 1, 1995, AND FEBRUARY 29, 1996, WHICH ARE PREDOMINATELY OPERATED ON UNIMPROVED ROADS MAY HAVE DEVELOPED CRACKS IN THE BUS BODY FRAMING STRUCTURE MEMBERS (RAFTERS) NEAR THE HORIZONTAL WINDOW HEADER WELDS AND AT THE SIDE EMERGENCY EXIT DOORS.

ON CERTAIN SCHOOL BUSES CHASSIS EQUIPPED WITH CATERPILLAR ENGINES AND HYDRAULIC BRAKES. A BRAIDED GROUND STRAP FOR THE STARTER MAY RUB ON A STEEL CHASSIS BRAKE LINE POTENTIALLY CAUSING A FLUID LEAK.

CERTAIN MOTOR HOME CHASSIS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, 'AIR BRAKE SYSTEMS.' IN A SITUATION IN WHICH MULTIPLE ALARMS ARE ACTIVE, A CHECK ENGINE, STOP ENGINE, OR SIMILAR WARNING INDICATOR IS GIVEN PRIORITY OVER THE LOW AIR ALARM BY THE INSTRUMENT SYSTEM CONTROLLER SOFTWARE. IF THE OPERATOR DOES NOT ACKNOWLEDGE THESE HIGHER PRIORITY ALARMS, A LOW AIR ALARM MAY NOT BE DISPLAYED.

ON CERTAIN SHUTTLE BUS CHASSIS, DUE TO THE LOCATION OF THE 90 GALLON FUEL TANK, A LEAK IN A WELD WHERE THE TANK CONTACTS THE LOWER FUEL TANK SUPPORT CAN OCCUR.

ON CERTAIN FIRE TRUCKS, ONE OR BOTH OF THE CAB TILT CYLINDERS MAY LOCK WHEN THE CAB IS BEING LOWERED. THIS CAN HAPPEN IF A VELOCITY FUSE TRIPS IN EITHER OF THE CYLINDERS.

ON CERTAIN SHUTTLE BUS CHASSIS, THE BRAKE ASSEMBLIES EXHIBIT ELEVATED TEMPERATURES THAT CAN LEAD TO CATASTROPHIC DETERIORATION OF THE WHEEL END COMPONENTS SUCH AS BEARINGS, RACES, SPINDLES, KNUCKLES, SEALS, HUBS, ROTORS, PATCH BOLTS, CALIPERS, BRAKE PADS, AND ABS SENSORS.

ON CERTAIN TRUCKS BUILT WITH 8,000 OR 6,000 POUND FRONT AXLES AND FOUR-PIECE SPINDLE NUT SETS, PREMATURE FRONT ,WHEEL BEARING WEAR MAY BE CAUSED BY INCONSISTENT BEARING ENDPLAY ADJUSTMENT.

ON CERTAIN TRUCKS, INCORRECT SPRINGS WERE INSTALLED IN THE EXHAUST PORT OF CERTAIN AIR MANAGEMENT UNIT (AMU) SOLENOID VALVES AND THEY MAY NOT TURN OFF AFTER ACTUATION.

ON CERTAIN TRUCKS EQUIPPED WITH MANUAL TRANSMISSION, THE TAPERED JOINT THAT ATTACHES THE SHIFTER TO THE TRANSMISSION MAY BECOME LOOSE MAKING IT DIFFICULT TO PUT THE TRANSMISSION INTO GEAR.

ON CERTAIN TRUCKS AND TRUCK-TRACTORS EQUIPPED WITH TRW DRAG LINK ASSEMBLIES, THE REPLACEMENT CLAMP AND DRAG LINK ASSEMBLIES CONTAIN A POTENTIALLY DEFECTIVE 5/8-11-GRADE B PREVAILING TORQUE HEX NUT. IF THE FINAL TIGHTENING IS LESS THAN 65 LB.-FT., THE CLAMP LOAD WOULD BE UNACCEPTABLY LOW AND COULD COMPROMISE THE INTEGRITY OF THE DRAG LINK.