Navistar 3800 recalls by model year

Reported: 1997-05-28 (May 28, 1997) · Model years: 1991, 1992, 1993, 1994, 1995, 1996

VEHICLE DESCRIPTION: MEDIUM AND HEAVY DUTY TRUCKS, SCHOOL AND TRANSIT BUSES BUILT WITH A BENDIX 9X3 POWER APPLY PARK BRAKE SYSTEM. THE CAM LEVER OF THE POWERED APPLY BRAKE CAN MOVE FORWARD, BECAUSE A HOLE IN THE TRANSMISSION MOUNTING BOSS WAS DRILLED TOO DEEP.

Consequence: THIS CAN ALLOW THE CAM LEVER TO BECOME DISENGAGED FROM THE PARKING BRAKE SHOES. THE OPERATOR WOULD HAVE NO WARNING THAT THE PARKING BRAKE WAS NOT APPLIED ALLOWING THE VEHICLE TO MOVE UNEXPECTEDLY.

Remedy: DEALERS WILL INSTALL SHIMS IN THE DRILLED AREA OF THE AUTOMATIC TRANSMISSION PARK BRAKE PIVOT PIN HOLE.

Reported: 1999-02-16 (February 16, 1999) · Model years: 1996, 1997, 1998

SCHOOL, TRANSIT, OR HEAVY DUTY VEHICLES EQUIPPED WITH SPICER 6,000 OR 8,000 LB. FRONT STEER AXLES. THE TIE ROD END CAN PULL OUTBOARD AND SEPARATE FROM THE TIE ROD TUBE DUE TO IMPROPER THREAD ENGAGEMENT BETWEEN THE MALE TIE ROD END AND THE FEMALE TUBE.

Consequence: SEPARATION OF THE TIE ROD END COULD RESULT IN LOSS OF STEERING CONTROL, INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE COMPLETE TIE ROD ASSEMBLY.

Reported: 1997-09-08 (September 8, 1997) · Model years: 1997

VEHICLE DESCRIPTION: BUSES AND HEAVY TRUCK CHASSIS EQUIPPED WITH T444E ENGINES. THE ACCELERATOR PEDAL ROD MATERIAL IS EXCESSIVELY BRITTLE AND CAN BREAK DURING A FULL THROTTLE APPLICATION.

Consequence: THE UNEXPECTED BREAKAGE CAN RESULT IN THE INABILITY TO ACCELERATE THE VEHICLE PROPERLY INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE ELECTRONIC ACCELERATOR PEDAL RODS WITH NEW RODS.

Reported: 1997-09-08 (September 8, 1997) · Model years: 1997

VEHICLE DESCRIPTION: BUSES AND HEAVY TRUCK CHASSIS EQUIPPED WITH CUMMINS N-14, CATERPILLAR, AND DETROIT DIESEL ELECTRONIC ENGINES. THE ACCELERATOR PEDAL ROD MATERIAL IS EXCESSIVELY BRITTLE AND CAN BREAK DURING A FULL THROTTLE APPLICATION.

Consequence: THE UNEXPECTED BREAKAGE CAN RESULT IN THE INABILITY TO ACCELERATE THE VEHICLE PROPERLY INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE ELECTRONIC ACCELERATOR PEDAL RODS WITH NEW RODS.

Reported: 1998-11-09 (November 9, 1998) · Model years: 1997, 1998

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH T444E DIESEL ENGINES. A FUEL LEAK CAN OCCUR BECAUSE OF OVERCRIMPING OF THE HOSE END FITTINGS ON THE HOSE FROM THE REGULATOR TO THE LEFT HEAD AND THE HOSE FROM THE FUEL TRANSFER PUMP TO THE REGULATOR.

Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE OIL HOSE AND PLACE AN ADDITIONAL CONVOLUTED LOOM AROUND THE EXISTING OIL HOSE, OR REPLACE THE HOSE ASSEMBLY.

Reported: 1999-11-23 (November 23, 1999) · Model years: 1997, 1998, 1999

VEHICLE DESCRIPTION: SCHOOL BUS. AN AIR BRAKE LINE CONTROLLING THE REAR BRAKES MAY BE TOO CLOSE TO THE EXHAUST PIPE AND COULD RUPTURE AT ANY TIME WITHOUT WARNING.

Consequence: EXHAUST PIPE HEAT CAN MELT OR CAUSE PREMATURE FAILURE OF THIS AIR LINE IF THE AIR LINE IS ROUTED TOO CLOSE TO THE EXHAUST PIPE.

Remedy: DEALERS WILL INSTALL A NEW ELBOW FITTING AND REROUTE THE AIR LINE. THE AIR LINE WILL ALSO BE INSPECTED AND REPLACED IF FOUND TO BE DAMAGED FROM THE EXHAUST PIPE.

Reported: 1998-09-17 (September 17, 1998) · Model years: 1998, 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH A 1710 DRIVE LINE AND A 12 X 4 HYDRAULIC PARKING BRAKE. IF THE BRAKE DRUM OR TRANSMISSION YOKE ARE NOT FULLY SEATED WHEN THE EIGHT BOLTS ARE INSTALLED CONNECTING THE 3-PIECE JOINT, THE BOLTS CAN LOOSEN.

Consequence: BOLTS WILL EVENTUALLY WORK OUT OR SHEAR RESULTING IN DRUM AND DRIVE SHAFT SEPARATION.

Remedy: DEALERS WILL INSPECT THE TORQUE OF THESE BOLTS AND RE-TORQUE TO SPECIFICATION.

Reported: 1998-11-09 (November 9, 1998) · Model years: 1998, 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS EQUIPPED WITH A T444E DIESEL ENGINE. THE HIGH PRESSURE OILLINE FOR THE FUEL INJECTION SYSTEM THAT GOES FROM THE HIGH PRESSURE OIL PUMP TO THE RIGHT CYLINDER HEAD CAN CHAFE AGAINST THE CHARGE AIR COOLER CROSSOVER PIPE.

Consequence: IF THIS CONDITION OCCURS, THE HOSE WILL FAIL, RESULTING IN A SUDDEN LOSS OF OIL, CAUSING THE ENGINE TO HAVE A SUDDEN LOSS OF POWER.

Remedy: DEALERS WILL INSPECT THE HOSES AND IF THE HOSE IS NOT DAMAGED A CONVOLUTED HOSE WILL BE PLACED OVER THE CURRENT HOSE. IF THE HOSE IS DAMAGED, IT WILL BE REPLACED ALONG WITH THE CONVOLUTED HOSE.

Reported: 1999-09-21 (September 21, 1999) · Model years: 1998, 1999

VEHICLE DESCRIPTION: TRANSIT AND SCHOOL BUSES BUILT WITH ABS AIR BRAKE ECU AND A 100 GALLON FUEL TANK MOUNTED BETWEEN THE RAILS AND BEHIND THE REAR AXLE ON MODELS WITH A 276" WHEEL BASE. THE ABS ECU INTERFERED WITH THE CROSS MEMBER MOUNTED BEHIND THE REAR AXLE AND IN FRONT OF THE BETWEEN THE RAILS FUEL TANK. THIS CREATED A NO-BUILD SITUATION AT THE PLANT - THE PLANT WOULD EITHER ELIMINATE OR RELOCATE THE CROSS MEMBER OR MOVE THE ECU AS NEEDED.

Consequence: IF THE CROSS MEMBER IS EITHER MISSING OR RELOCATED THE VEHICLE MAY NOT HAVE ADEQUATE FUEL TANK PROTECTION. IN THE EVENT OF A CRASH, THE BUS MAY NOT HAVE ADEQUATE FUEL TANK PROTECTION IF THE VEHICLE HAS A MISSING OR IMPROPERLY INSTALLED CROSSMEMBER.

Remedy: DEALERS WILL INSPECT THE VEHICLES TO MAKE SURE ALL CROSS MEMBERS ARE PROPERLY INSTALLED. IF THE CROSS MEMBER IS NOT INSTALLED CORRECTLY OR IS MISSING, THE DEALER WILL REPAIR OR INSTALL THE CROSS MEMBER.

Reported: 1999-03-16 (March 16, 1999) · Model years: 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS, TRANSIT AND SCHOOL BUSES, EQUIPPED WITH MERITOR AIR BRAKE AUTOMATIC SLACK ADJUSTERS. SOME OF THE AUTOMATIC SLACK ADJUSTERS HAD INSUFFICIENT TORQUE APPLIED TO THE GUIDE PAWL CAP SCREW.

Consequence: WITHOUT SUFFICIENT TORQUE ON THE GUIDE PAWL CAP SCREW, THE BRAKES COULD GRADUALLY LOSE ADJUSTMENT, INCREASING THE VEHICLE STOPPING DISTANCE.

Remedy: DEALERS WILL CHECK THE TORQUE ON THE AUTOMATIC SLACK ADJUSTER GUIDE PAWL. IF THERE IS NO TORQUE, THE BRAKES WILL BE ADJUSTED AND THE GUIDE PAWL WILL BE TIGHTENED TO 15-20 FT. LBS.

Reported: 1999-09-21 (September 21, 1999) · Model years: 1999

VEHICLE DESCRIPTION: HEAVY DUTY TRUCKS BUILT WITH REAR LEAF SPRING SUSPENSIONS (MODELS 4700 BUILT WITH REAR LEAF SUSPENSIONS AND MANUFACTURED FROM DECEMBER 9, THROUGH DECEMBER 16, 1998; MODELS 3400 AND 3800 BUILT WITH 14SBK REAR LEAF SPRING SUSPENSIONS AND BUILT APRIL 14 THROUGH MAY 10, 1999; AND MODELS 3400 AND 3800 BUILT WITH REAR LEAF SPRING SUSPENSIONS AND MANUFACTURED FROM MAY 10 THROUGH MAY 18, 1999). ON VEHICLES WHERE THE FRAME TO AXLE HOSE LENGTH WAS TOO LONG, A CHAFING CONDITION EXISTS ON SUSPENSION COMPONENTS, WHICH COULD RESULT IN HOSE RUPTURE. ON VEHICLES WHERE THE HOSES ARE TOO SHORT, A HOSE SEPARATION COULD OCCUR WITH SEVERE SUSPENSION ARTICULATION.

Consequence: IF A HOSE RUPTURES, THE REAR BRAKES WILL FAIL INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: SHORT HOSES WILL BE REPLACED AND THE LONG HOSES WILL HAVE A HOSE ROUTING KIT INSTALLED TO PREVENT ANY CHAFING PROBLEMS.