International Harvester 3800 recalls by model year

Reported: 1992-07-20 (July 20, 1992) · Model years: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1991, 1992

THE FUEL SYSTEM FAILED THE CRASH BARRIER TEST.

Consequence: THE FUEL TANK WAS PUNCTURED, RESULTING IN FLUID LOSSGREATER THAN ALLOWED BY FMVSS 301, "FUEL SYSTEM INTEGRITY". FUEL SPILLS INA COLLISION COULD LEAD TO A VEHICLE FIRE IF EXPOSED TO A SOURCE OF IGNITION.

Remedy: MODIFY THE FUEL TANK CAGE TO COMPLY WITH FMVSS 301.

Reported: 1996-11-12 (November 12, 1996) · Model years: 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1991, 1992, 1993, 1994

THESE BUSES HAVE A TURN SIGNAL LEVER THAT WILL NOT OPERATE CONSISTENTLY IN THE LANE CHANGE MODE IF THE LEVER IS NOT MOVED TO THE POSITION WHERE RESISTANCE TO MOVEMENT IS FELT.

Consequence: SHOULD THE REAR SIGNAL LAMPS NOT FLASH WHEN A LANE CHANGE WAS BEING MADE, IT COULD RESULT IN A VEHICLE FOLLOWING THE BUS TO COLLIDE WITH THE BUS INCREASING THE RISK OF PERSONAL INJURY AND/OR PROPERTY DAMAGE.

Remedy: OPERATORS WILL BE MAILED INFORMATION CONCERNING THE PROPER METHOD OF USING TURN SIGNALS. A DECAL WILL ALSO BE PROVIDED TO BE PLACED ON THE INSTRUMENT PANEL OF EACH BUS.

Reported: 1996-06-11 (June 11, 1996) · Model years: 1982

THE AXLE HOUSINGS WERE MANUFACTURED WITH A TIGHT FRICTION WELD CURL RADIUS ON THE INSIDE DIAMETER OF THE AXLE HOUSING. UNDER OPERATIONAL LOADS, CRACKS CAN INITIATE AT THE WELD CURL RADIUS ON THE INSIDE OF THE HOUSING. THESE CRACKS MAY PROPAGATE, EVENTUALLY ALLOWING THE AXLE SPINDLE TO SEPARATE FROM THE AXLE HOUSING.

Consequence: SEPARATION OF THE AXLE SPINDLE FROM THE AXLE HOUSING CAN RESULT IN LOSS OF VEHICLE CONTROL AND A POSSIBLE ACCIDENT.

Remedy: DEALERS WILL REPLACE THE REAR AXLE HOUSING WITH A NEW HOUSING.

Reported: 1995-06-27 (June 27, 1995) · Model years: 1989, 1991

THE WIRE END OF THE HAND THROTTLE CABLE PASSES THROUGH A SPLIT PLASTIC GROMMET IN THE ACCELERATOR ROD. THIS WIRE CAN WORK THROUGH THE SLOT IN THE GROMMET AND BECOME LODGED BETWEEN THE GROMMET AND THE EDGE OF THE HOLE IN THE ACCELERATOR ROD.

Consequence: IF THE THROTTLE WIRE BECOMES LODGED, THE ACCELERATOR CAN STICK AND NOT RETURN TO IDLE POSITION POTENTIALLY AFFECTING THE OPERATOR'S ABILITY TO CONTROL THE VEHICLE AND INCREASING THE POTENTIAL FOR AN ACCIDENT.

Remedy: DEALERS WILL REPAIR BUSES BY INSTALLING A NEW CABLE GROMMET WITHOUT A SLOT; INSTALL A NEW CABLE STOP; AND READJUST THE THROTTLE CABLE.

Reported: 1993-05-21 (May 21, 1993) · Model years: 1991, 1992, 1993

THE PRESSURE RELIEF VALVE WAS OMITTED IN THE AIR TANK. THE AIR TANK IS THE RESERVOIR FOR THE AIR SUSPENSION AND IS NOT BRAKE RELATED. WITHOUT THE PRESSURE RELIEF VALVE, THERE IS NO BACK-UP SYSTEM TO LIMIT AIR PRESSURE IN THE AIR SUSPENSION SYSTEM.

Consequence: LACK OF A BACK-UP SYSTEM TO LIMIT AIR PRESSURE BUILD UPCAN CAUSE EXCESSIVE PRESSURE IN THE AIR TANK AND CAN CAUSE THE TANK TO RUPTURE.THIS CAN RESULT IN PERSONAL INJURY TO ANYONE IN THE VICINITY.

Remedy: INSTALL A PRESSURE RELIEF VALVE IN THE AIR TANK.

Reported: 1993-07-07 (July 7, 1993) · Model years: 1991, 1992

THE FUEL TANK CAGE ASSEMBLY BOLTS MOUNTING THE VERTICAL STRAPS TO THE HORIZONTAL ANGLE WERE ASSEMBLED WITH THE THREADED END OF THE BOLTS FACING THE FUEL TANK.

Consequence: IF THE FUEL TANK CAGE IS STRUCK WITH SUFFICIENT FORCE ITIS POSSIBLE FOR THE BOLTS TO PIERCE THE FUEL TANK AND CAUSE FUEL LEAKAGE.FUEL LEAKAGE EXPOSED TO A SOURCE OF IGNITION CAN RESULT IN A FIRE.

Remedy: THE FUEL TANK CAGE MOUNTING BOLTS WILL BE REMOVED AND REINSTALLED WITH THE BOLT HEAD TOWARD THE TANK.

Reported: 1996-09-13 (September 13, 1996) · Model years: 1992, 1993, 1994, 1995, 1996

THE WIRING FROM THE ELECTRONIC CONTROL UNIT WAS CONNECTED TO THE WRONG WHEEL SENSOR OR TO THE WRONG BRAKE MODULATOR VALVE. IT IS POSSIBLE THAT EITHER OR BOTH WIRING MAY HAVE OCCURRED AT EITHER THE FRONT OR REAR AXLE OR BOTH AXLES.

Consequence: SHOULD THE ANTI-LOCK BRAKING SYSTEM (ABS) WIRING BE CROSSED, IT WOULD RESULT IN A SIGNIFICANT DEGRADATION IN VEHICLE STOPPING DISTANCE. A SIGNAL WOULD BE SENT TO THE WRONG BRAKE CHAMBER WHEN A BRAKE IMBALANCE IS DETECTED. THIS CONDITION INCREASES THE RISK OF A VEHICLE ACCIDENT.

Remedy: DEALERS WILL INSPECT THE ABS WIRING AND, IF NECESSARY, PROPERLY CONNECT.

Reported: 1996-03-01 (March 1, 1996) · Model years: 1993, 1994, 1995, 1996

THE FRONT WHEEL HUB CAN DEVELOP CRACKS AT THE WHEEL MOUNTING STUDS. WHEN MOUNTED TO THE HUB, THE HYDRAULIC BRAKE DISC ROTOR DOES NOT PROPERLY SUPPORT THE HUB AT THE WHEEL STUDS CAUSING EXCESSIVE STRESS AND FATIGUE CRACKS IN THE HUB.

Consequence: SHOULD SUFFICIENT CRACKS OCCUR, THE MOUNTING FLANGE PORTION OF THE HUB ALONG WITH THE WHEEL COULD SEPARATE FROM THE VEHICLE WITHOUT WARNING. SHOULD THIS OCCUR WHILE THE VEHICLE IS DRIVEN, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE AND/OR THE SEPARATED WHEEL AND HUB COULD STRIKE ANOTHER VEHICLE, PEDESTRIAN OR PROPERTY.

Remedy: DEALERS WILL INSTALL NEW, REDESIGNED HUBS ON THESE VEHICLES.

Reported: 1994-08-02 (August 2, 1994) · Model years: 1994, 1995

FOUR COMPRESSION BACKPLATE RETAINING FASTENERS ON THE TURBO-CHARGER WERE TORQUED ONLY HAND TIGHT. THIS ALLOWS THE FASTENERS TO LOOSEN, AND CAUSES OIL TO LEAK INTO THE COMPRESSOR AIR SIDE OF THE TURBO-CHARGER WHICH, WHEN COUPLED WITH THE HEAT PRECIPITATED BY THE COMPRESSOR AND THE MIXING ACTION OF THE COMPRESSOR WHEEL, CAN RESULT IN AN AIR/OIL MIXTURE THAT FUELS THE ENGINE.

Consequence: WHEN THIS OCCURS, ENGINE RUN-ON AND SUBSEQUENT LOSS OF OPERATOR CONTROL VIA THE NORMAL THROTTLE MECHANISM CAN OCCUR, WHICH COULD RESULT IN A VEHICLE ACCIDENT.

Remedy: REPLACE THE SUSPECT TURBO-CHARGER WITH A NEW TURBO-CHARGER.

Reported: 1994-07-19 (July 19, 1994) · Model years: 1995

THESE BUSES WERE BUILT WITH AN ADDITIONAL 3/4 INCH THICK PLYWOOD FLOOR AND EXTRA THICK FLOOR MATS FOR INCREASED INSULATION DURING COLD WEATHER. THE BOTTOM EDGE OF THE ACCELERATOR PEDAL, WHEN DEPRESSED, CAN COME IN CONTACT WITH THE HEAD OF A BOLT SECURING THE TRANSMISSION COVER TO THE FLOOR. THE ENGINE THROTTLE MAY NOT RETURN TO THE IDLE POSITION.

Consequence: THIS CAN RESULT IN LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

Remedy: DEALERS WILL REMOVE 1/2 INCH FROM THE BOTTOM OF THE ACCELERATOR PEDAL.

Reported: 1996-11-27 (November 27, 1996) · Model years: 1996, 1997

VEHICLE DESCRIPTION: SCHOOL BUSES EQUIPPED WITH THE INTERNATIONAL I6 ELECTRONIC ENGINE AND AN EXTRA THICK BUS BODY FLOOR. THE ACCELERATOR PEDAL TO FLOOR CLEARANCE IS APPROXIMATELY 1.2 INCHES WITH A STANDARD BUS BODY FLOOR. HOWEVER, SOME CUSTOMERS ORDERED AN ADDITIONAL 3/4 INCH THICK FLOOR AND EXTRA THICK FLOOR MATS TO SERVE AS INSULATION IN COLD CLIMATES. WHEN THIS EXTRA FLOORING IS USED, THE BOTTOM EDGE OF THE ACCELERATOR PEDAL, WHEN DEPRESSED, CAN COME IN CONTACT WITH THE FLOOR.

Consequence: SHOULD THE ACCELERATOR PEDAL CONTACT THE FLOOR, THE PEDAL COULD GET CAUGHT AND NOT RETURN TO THE IDLE POSITION INCREASING THE RISK OF A VEHICLE ACCIDENT.

Remedy: DEALERS WILL INSPECT THE FLOORING ON THESE BUSES TO INSURE THERE IS A MINIMUM OF 1/4 INCH CLEARANCE. ON BUSES WITH LESS THAN 1/4 INCH CLEARANCE, THE DEALER WILL REMOVE THE PEDAL AND CUT OFF THE BOTTOM OF THE PAD TO OBTAIN THE PROPER CLEARANCE.

Reported: 2003-02-25 (February 25, 2003) · Model years: 1997, 1998, 1999, 2000, 2001

ON CERTAIN SCHOOL AND TRANSIT BUSES BUILT WITH BOSCH ZERO OFFSET PIN SLIDE (ZOPS) HYDRAULIC DISC BRAKES, THE ZOPS HYDRAULIC DISC BRAKES MAY EXPERIENCE CALIPERS STICKING IN THE APPLIED POSITION, WHICH CAN RESULT IN EXCESSIVE OR ABNORMAL HEAT GENERATION AT ONE OR MORE OF THE BRAKES.

Consequence: THE COMBINATION OF THE FOLLOWING FACTORS MAY COLLECTIVELY RESULT IN AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY: POTENTIAL FIRE AT A WHEEL END, HIGH INCIDENT RATES OF STUCK CALIPERS, AND EVACUATION AND CONTAINMENT CONCERNS RELATING TO MULTIPLE PASSENGERS.

Remedy: INTERNATIONAL WILL NOTIFY ITS CUSTOMERS AND REPAIR THE BUSES FREE OF CHARGE. THE RECALL BEGAN OCTOBER 29, 2004.

Reported: 1996-11-27 (November 27, 1996) · Model years: 1997

VEHICLE DESCRIPTION: SCHOOL BUSES AND HEAVY DUTY TRUCKS EQUIPPED WITH REAR AXLE ASSEMBLIES PRODUCED BY DANA SPICER. CERTAIN REAR AXLE ASSEMBLIES WERE IMPROPERLY HEAT TREATED WHICH COULD ALLOW PINION BREAKAGE AT THE PINION THREADS.

Consequence: CRACKS CAN INITIATE AND RESULT IN SEPARATION OF THE THREADED END OF THE PINION RESULTING IN SEPARATION OF THE YOKE AND DRIVE LINE FROM THE REAR AXLE INCREASING THE RISK OF A VEHICLE ACCIDENT.

Remedy: DEALERS WILL REPLACE THE REAR AXLE CARRIER/PINION ASSEMBLY.

Reported: 2004-06-03 (June 3, 2004) · Model years: 1999, 2000, 2001

ON CERTAIN SCHOOL BUSES AND TRUCK MODEL VEHICLES MANUFACTURED BETWEEN FEBRUARY 28, 1999, THROUGH APRIL 5, 2004, THE ANTI-LOCK BRAKE SYSTEM ELECTRONIC CONTROL UNIT (ECU) MAY MISINTERPRET A CORRUPT WHEEL SPEED SIGNAL.

Consequence: THE CORRUPT WHEEL SPEED SIGNALS MAY IMPROPERLY ACTIVATE THE ABS, INSTEAD OF DEACTIVATING THE ABS. THIS MAY RESULT IN THE DRIVER EXPERIENCING A HARD PEDAL FEEL AND A DECREASE IN DECELERATION AT THE END OF THE STOP, RESULTING IN EXTENDED STOPPING DISTANCES WHICH COULD CAUSE A VEHICLE CRASH, POSSIBLY RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy: INTERNATIONAL WILL NOTIFY ITS CUSTOMERS AND INSPECT AND REPAIR THE AFFECTED VEHICLES FREE OF CHARGE. THE RECALL BEGAN AUGUST 1, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL CUSTOMER SERVICE AT 1-800-327-4236.

Reported: 2000-05-23 (May 23, 2000) · Model years: 2000

VEHICLE DESCRIPTION: SCHOOL/TRANSIT BUSES AND MEDIUM DUTY TRUCKS. THE CASTINGS USED ON THE POWER STEERING PUMPS WERE NOT BUILT TO MATCH THE ENGINEERING DRAWINGS, RESULTING IN A THIN WALL IN THE PUMP CASTING OR A COMPLETE CONNECTION OF TWO PASSAGES THAT ARE SUPPOSED TO BE SEPARATED TO CONTROL FLUID FLOW. THE FLUID FLOW MAY BE REDUCED TO LESS THAN THE MINIMUM REQUIRED FLOW RATE TO PROVIDE FULL POWER ASSIST TO THE BRAKE SYSTEM WITH LOW ENGINE SPEED.

Consequence: AN INCREASE IN STOPPING DISTANCE AT SLOW ENGINE SPEEDS CAN RESULT, INCREASING THE POSSIBILITY OF A CRASH.

Remedy: DEALERS WILL INSPECT AND REPLACE ALL PUMPS THAT HAVE THE DEFECTIVE CASTING NUMBERS.