Ford F800 recalls by model year

Reported: 1979-02-22 (February 22, 1979) · Model years: 1979

THE AIR BRAKE LINES MAY BE ROUTED TOO CLOSE TO THE EXHAUST MUFFLER. BECAUSE THE AIR BRAKE LINES ARE MADE OF NYLON MATERIAL, HEAT FROM THE EXHAUST MUFFLER CAN WEAKEN THE BRAKE LINE TUBES, POSSIBLY CAUSING THEM TO RUPTURE. TUBE RUPTURE COULD RESULT IN LOSS OF AIR IN THE SECONDARY AIR BRAKE SYSTEM.

Remedy: NEW NYLON AIR BRAKE TUBES WILL BE INSTALLED AND REROUTED WITHOUT CHARGE TO OWNER.

Reported: 1981-06-15 (June 15, 1981) · Model years: 1980, 1981

THE PRIMARY CIRCUIT CONNECTION, WHICH PROVIDES PRIMARY ELECTRICAL POWER TO THE ENGINE, COULD DETERIORATE DUE TO HIGH CURRENT DRAW PRODUCED BY BUILDER-INSTALLED EQUIPMENT.

Remedy: THE MAIN CAB WIRING HARNESS ELECTRICAL CONNECTOR WILL BE MODIFIED TO ELIMINATE DETERIORATION AT NO CHARGE TO OWNER.

Reported: 1981-10-15 (October 15, 1981) · Model years: 1980, 1981

THE MASTER CYLINDER TO CHASIS BRAKE TUBE AND HOSE ASSEMBLIES MAY HAVE BEEN MOVED FROM THEIR INTENDED POSITION, WHICH COULD ALLOW CHAFING AGAINST UNDERBODY COMPONENTS. CHAFING PROMOTES WEAR OF THE BRAKE TUBE AND HOSE ASSEMBLY AND COULD CAUSE A LOSS OF BRAKE FLUID.

Remedy: UPON INSPECTION BRAKE TUBE CLIPS WILL BE INSTALLED, IF NECESSARY, AND BRAKE TUBES AND HOSE ASSEMBLIES WILL BE REPLACED OR REROUTED.

Reported: 1981-07-17 (July 17, 1981) · Model years: 1981

THE INVOLVED VEHICLES WERE ASSEMBLED WITH THE LEFT FRONT BRAKE TUBE RETAINING CLIP MISSING. THE ABSENCE OF A RETAINING CLIP MAY ALLOW THE BRAKE TUBE TO RUB AGAINST THE SHOCK ABSORBER, CAUSING WEAR ON THE TUBE AND, EVENTUALLY, LOSS OF BRAKE FLUID.

Remedy: MISSING BRAKE TUBE CLIPS WILL BE INSTALLED AND ANY CHAFED BRAKE TUBES WILL BE REPLACED.

Reported: 1983-02-15 (February 15, 1983) · Model years: 1983

ON THE AFFECTED VEHICLES, THE WIRING ASSEMBLY TO THE FLOOR MOUNTED HEADLAMP DIMMER SWITCH MAY BE TOO TIGHT; SHOULD WIRES DISCONNECT, THE HEADLIGHTS WILL NOT OPERATE.

Remedy: THE DEALER WILL MODIFY THE DIMMER SWITCH WIRING WITH A WIRE EXTENSION ASSEMBLY AT NO CHARGE TO OWNER.

Reported: 1984-04-10 (April 10, 1984) · Model years: 1983

TWO-INCH SPACERS SPECIFIED FOR INSTALLATION BETWEEN THE FRONT AXLES AND EACH FRONT SPRING ASSEMBLY WERE OMITTED DURING MANUFACTURE. UNDER CERTAIN TURNING AND BOUNCING CONDITIONS, A FRONT TIRE COULD CONTACT ADJACENT VEHICLE COMPONENTS, RESULTING IN A POSSIBLE SEPARATION OF THE DRAG LINK TO STEERING ARM BALLJOINT OR LOSS OF TIRE PRESSURE.

Remedy: FRONT AXLE SPACERS WILL BE INSTALLED WITHOUT CHARGE.

Reported: 1984-10-23 (October 23, 1984) · Model years: 1984

THE INVOLVED VEHICLES WERE PRODUCED WITH HYDRAULIC BRAKE BOOSTER SUPPLY HOSES THAT ARE LOCATED TOO CLOSE TO THE ENGINE EXHAUST MANIFOLD AND MAY CHAFE AND DEVELOP HEAT DAMAGE DURING VEHICLE OPERATION. CHAFING AND HEAT INDUCED DETERIORATION OF A HOSE DUE TO DIRECT CONTACT WITH THE MANIFOLD MAY CAUSE THE HOSE TO WEAR. A SUBSEQUENT RUPTURE WILL RESULT IN PUMP FLUID LOSS.

Remedy: THE DEALER WILL RELOCATE AND REPLACE THE BRAKE BOOSTER SUPPLY TUBE AND HOSE AS NECESSARY AT NO COST TO OWNER.

Reported: 1991-05-01 (May 1, 1991) · Model years: 1990, 1991

THE THROTTLE CABLE WHICH RUNS FROM THE ACCELERATOR TO THE GOVERNOR ASSEMBLY HOUSING MAY HAVE BEEN KINKED DURING ASSEMBLY, CAUSING EXCESSIVE WEAR OF THE CABLE HOUSING INNER LINING. THIS COULD RESULT IN EITHER FRACTURE OR STICKING OF THE CABLE.

Consequence: IF THE THROTTLE CABLE FRACTURES, ENGINE SPEED WILL RETURNTO IDLE. IF THE CABLE JAMS OR STICKS, THE ENGINE WILL REMAIN AT THE SPEED ATWHICH IT WAS RUNNING WHEN THE JAMMING OCCURRED. A STUCK THROTTLE COULD RESULT INLOSS OF CONTROL AND AN ACCIDENT.

Remedy: REPLACE THE GOVERNOR ASSEMBLIES, WHICH INCLUDE THE THROTTLE CABLE.

Reported: 1992-01-14 (January 14, 1992) · Model years: 1992

WATER CAN ENTER THE DOOR LATCH RELEASE CABLE. IF THE VEHICLE IS OPERATED IN BELOW FREEZING TEMPERATURES, THE WATER IN THE DOOR LATCH RELEASE CABLE CAN FREEZE AND CAUSE THE LATCH MECHANISM TO MALFUNCTION.

Consequence: THE MALFUNCTION OF THE DOOR LATCH RELEASE CAN RESULT INTHREE DIFFERENT PROBLEMS: 1) THE DOOR WILL NOT BE ABLE TO BE RELATCHED, 2) THEINSIDE DOOR HANDLE CAN BECOME INOPERATIVE, AND 3) THE DOOR COULD APPEAR TO BELATCHED WHEN IT IS NOT, ALLOWING THE DOOR TO OPEN UNEXPECTEDLY IF IT IS JARRED,AND INCREASING THE RISK OF INJURY TO THE ADJACENT SEAT OCCUPANT.

Remedy: REVISED DOOR RELEASE CABLES AND WATER SHIELDS WILL BE INSTALLED.

Reported: 1993-09-27 (September 27, 1993) · Model years: 1992, 1993

AS A RESULT OF INHERENT VIBRATION IN THESE ENGINES, THE THROTTLE RETURN SPRINGS CAN FRACTURE.

Consequence: IF ONE OF THE TWO RETURN SPRINGS FRACTURES WHILE THEVEHICLE IS BEING DRIVEN, A SUBSTANTIAL REDUCTION IN ACCELERATOR PEDAL EFFORTWOULD BE FELT. IF THE SECOND SPRING ALSO FRACTURES, THE THROTTLE WOULD NOTRETURN TO IDLE POSITION AND CAN RESULT IN INCREASED ENGINE SPEED AND THEPOSSIBILITY OF LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

Remedy: THE THROTTLE RETURN CONTROL SYSTEM WITH THE COIL TORSION SPRING DESIGN WILL BE REPLACED.

Reported: 1992-11-10 (November 10, 1992) · Model years: 1993

Consequence: USING THE WRONG SIZED CLAMPS TO ATTACH THE RIM AND TIREASSEMBLY TO THE WHEEL SPOKES COULD CAUSE THE STUDS THAT ATTACH THE CLAMPS TO THESPOKES TO BEND. IF THE STUDS ARE BENT, THERE IS AN INCREASED RISK OF STUDFRACTURE THAT COULD RESULT IN THE RIM AND TIRE ASSEMBLY BREAKING FROM THEWHEEL.

Remedy: REPLACE THE CLAMPS AND STUDS ON THE CAST SPOKE WHEELS.

Reported: 1995-08-02 (August 2, 1995) · Model years: 1993, 1994, 1995

THE HAND THROTTLE CABLE CAN WEAR THE BRASS SWIVEL BLOCK ON THE GOVERNOR LEVER THROUGH WHICH IT PASSES.

Consequence: THIS WEAR CAN RESULT IN THE GOVERNOR JAMMING IN THEDAMAGED SWIVEL AND COULD PREVENT THE GOVERNOR LEVER FROM RETURNING TO THE IDLE POSITION.

Remedy: DEALERS WILL INSTALL A REVISED GOVERNOR LEVER WITH A STAINLESS STEEL SWIVEL. ALSO LETTERS WILL BE SENT TO VEHICLE OWNERS THAT HAVE THE SAME VEHICLES BUT DO NOT HAVE A FORD INSTALLED HAND THROTTLE ADVISING THEM THAT THEY MAY REQUIRE SERVICE IF THEY HAVE HAD AN AFTER MARKET HAND THROTTLE INSTALLED.

Reported: 1995-05-09 (May 9, 1995) · Model years: 1994, 1995

A CONNECTOR IN THE WIRING WHERE THE TILT HOOD MOUNTED LAMPS ATTACH TO THE VEHICLE WIRING HARNESS WAS BUILT WITHOUT SEALING PLUGS. MOISTURE, ROAD SALT OR OTHER CONTAMINANTS CAN ENTER THE CONNECTION RESULTING IN CROSSED CIRCUITS, SHORTS OR CORROSION OF THE WIRING OF THE CONNECTOR.

Consequence: THE HEADLAMPS OR OTHER FRONT-END LIGHTING SYSTEMS CAN MALFUNCTION AS A RESULT OF THIS CONDITION INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: DEALERS WILL INSPECT THE CONNECTOR AND INSTALL SEALING PLUGS IN THE OPEN CAVITIES. IF THE INSPECTION REVEALS CORROSION, A NEW CONNECTOR WILL BE INSTALLED.

Reported: 1994-11-28 (November 28, 1994) · Model years: 1995

THE VEHICLES WERE MANUFACTURED WITHOUT SEPARATE ABS INDICATOR LAMPS. THIS DOES NOT COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC BRAKE SYSTEMS."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: THE BRAKE SYSTEM COULD FAIL AND THE DRIVER WOULD HAVE NO WARNING.

Remedy: DEALERS WILL INSTALL ABS INDICATOR LAMP AND CIRCUITRY.

Reported: 1994-12-12 (December 12, 1994) · Model years: 1995

THE DRAG LINK INSTALLED CAN CONTACT THE FRONT AXLE I-BEAM UNDER CERTAIN EXTREME CONDITIONS. THIS DRAG LINK WAS NOT INTENDED TO BE INSTALLED ON "LOW PROFILE" VEHICLES.

Consequence: THIS CAN RESULT IN LOSS OF STEERING CONTROL.

Remedy: DEALERS WILL INSTALL THE CORRECT DRAG LINK ON THE VEHICLES.

Reported: 1997-05-28 (May 28, 1997) · Model years: 1998

VEHICLE DESCRIPTION: MEDIUM DUTY TRUCKS AND SCHOOL BUS CHASSIS-COWLS EQUIPPED WITH AUTOMATIC TRANSMISSIONS. THE WELDS THAT ATTACH THE KEY TO THE TOP OF THE STEERING COLUMN MOUNTED AUTOMATIC TRANSMISSION SHIFT LINKAGE MAY NOT ADEQUATELY RETAIN THE KEY, ALLOWING THE TRANSMISSION TO BE IN A GEAR OTHER THAN THAT INDICATED ON THE "PRNDL", OR IN SOME CASES, "RNDL."

Consequence: THE DOMESTIC SPECIAL ORDER (DSO) PARK BRAKE MAY NOT ENGAGE WHEN THE SHIFT LEVER IS PLACED IN THE PARK POSITION, OR IN THE VEHICLE MOVING IN AN UNINTENDED DIRECTION WHEN THE ACCELERATOR IS PRESSED. IN SOME VEHICLES THE DSO PARKING BRAKE MECHANISM ALSO MAY NOT BE PROPERLY ADJUSTED, WHICH CAN RESULT IN THE PARK BRAKE NOT ENGAGING WHEN THE SHIFT LEVER IS PLACED IN THE PARK POSITION, INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE STEERING COLUMN SHIFT TUBE AND, IF SO EQUIPPED, TO HAVE THE DSO PARK BRAKE LINKAGE ADJUSTED.

Reported: 1998-02-24 (February 24, 1998) · Model years: 1998

VEHICLE DESCRIPTION: MEDIUM DUTY TRUCKS AND CHASSIS-CABS. AN AUTOMATIC LOCKING FRONT WHEEL BEARING ADJUSTING NUT WAS DAMAGED DURING INSTALLATION OR REMOVAL BY INCORRECT TOOLS OR AN INCORRECT TORQUE SPECIFICATION WAS USED.

Consequence: THIS CONDITION CAN CAUSE THE NUT TO ROTATE FREELY AND LOSE TORQUE. IT COULD ROTATE UNTIL IT IS NO LONGER CONNECTED TO THE FRONT SPINDLE AND ALLOW THE FRONT WHEEL TO SEPARATE FROM THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE FRONT WHEEL BEARING ADJUSTING NUTS WITH CASTLE NUTS AND COTTER PINS.