2004 Autocar WXLL: complaints, problems and recalls

Reported: 2004-08-10 (August 10, 2004)

ON CERTAIN TRUCKS EQUIPPED WITH ACCURIDE 22.5 X 9.00 - HUB PILOT H.D. STEEL WHEEL RIMS, THE REAR AXLE WHEEL STUDS ARE TOO SHORT. THESE STUDS MAY NOT BE ABLE TO RETAIN THE WHEEL NUT TORQUE AND COULD LOOSEN ALLOWING THE LOSS OF A WHEEL.

Consequence: IF A VEHICLE LOSES A WHEEL WHILE TRAVELING DOWN A ROADWAY, A CRASH COULD OCCUR, PROPERTY DAMAGE TO FOLLOWING VEHICLES OR PERSONAL INJURY TO PERSONS OUTSIDE THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE REAR AXLE WHEEL STUDS. THE RECALL BEGAN ON SEPTEMBER 3, 2004. OWNERS SHOULD CONTACT AUTOCAR AT 1-877-973-3486.

Reported: 2004-11-09 (November 9, 2004)

ON CERTAIN HEAVY-DUTY CLASS 8 VEHICLES, THE AUTOMATIC ANTILOCK BRAKE SYSTEM (ABS) BRAKE SENSOR BRACKET MAY NOT HAVE BEEN INSTALLED CORRECTLY ON THE FRONT AXLE AND MAY INTERFERE WITH THE BRAKE SHOE RETURN SPRING. THIS COULD CAUSE THE BRAKES TO NOT RELEASE OR MAY CAUSE AN UNEXPECTED FRONT WHEEL LOCKUP AND POSSIBLE LOSS OF VEHICLE CONTROL.

Consequence: ANY TIME VEHICLE CONTROL IS COMPROMISED A CRASH MAY OCCUR WITHOUT PRIOR WARNING.

Remedy: DEALERS WILL REPOSITION THE ABS SENSOR BRACKET INTO ITS PROPER LOCATION AND THE REPLACEMENT OF THE BRAKE RETURN SPRINGS AND S-CAM ROLLERS. THE RECALL BEGAN ON NOVEMBER 24, 2004. OWNERS SHOULD CONTACT AUTOCAR AT 1-877-973-3486.

Reported: 2004-12-20 (December 20, 2004)

ON CERTAIN TRUCKS, THE AIR SUSPENSION HEIGHT CONTROL VALVE MAY NOT BE INSTALLED CORRECTLY.

Consequence: IN THE EVENT OF A SUSPENSION AIR BAG FAILURE OR RUPTURE OF THE AIR LINE, THERE COULD BE A LOSS OF AIR PRESSURE IN THE 'B' SYSTEM AIR RESERVOIR THAT SUPPLIES AIR PRESSURE FOR THE FRONT STEER AXLE BRAKES. THIS CONDITION WOULD INCREASE STOPPING DISTANCE OF THE VEHICLE AND UNDER CERTAIN CONDITIONS COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT AND INSTALL A PRESSURE PROTECTION VALVE IF NECESSARY. THE RECALL BEGAN JANUARY 4 2005. OWNERS SHOULD CONTACT AUTOCAR AT 1-877-973-3486.

Reported: 2005-02-03 (February 3, 2005)

ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS EQUIPPED WITH ARVINMERITOR URRESKO TIE ROD CLAMPS, HEAT TREATMENT OF CLAMPS CREATED A SURFACE HARDNESS THAT COULD LEAD TO A FRACTURE OF THE CLAMPS.

Consequence: IN THE EVENT OF A CRACK THE CLAMPS COULD BREAK OFF AFFECTING TOE-IN AND ALIGNMENT. THE TIE ROD CAN COME LOOSE RESULTING IN STEERING LOSS AND A CRASH COULD OCCUR WITHOUT PRIOR WARNING.

Remedy: DEALERS WILL INSPECT AND REPAIR THESE VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON MARCH 24, 2005. OWNERS MAY CONTACT AUTOCAR AT 1-765-489-5499.

Reported: 2005-02-03 (February 3, 2005)

ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS EQUIPPED WITH BENDIX AUTOMATIC BRAKE SYSTEMS (ABS), THE BRAKES MAY HAVE A SYSTEM FAULT THAT MAY NOT BE DETECTED BY THE ABS ELECTRONIC CONTROL UUNIT (ECU) AND THEREFORE WILL NOT GENERATE AN ABS WARNING LIGHT ON THE DASH OF THE TRUCK.

Consequence: THE ABS BRAKES MAY NOT PERFORM AS DESIGNED AND IN AN ABS ASSISTED STOP THE DRIVER MAY NOT BE ABLE TO MAINTAIN STEERING CONTROL OF THE VEHICLE. WHEN VEHICLE CONTROL IS COMPROMISED THERE IS A CHANCE FOR A CRASH.

Remedy: DEALERS WILL INSPECT, RESET AND CHECK THE ECU FOR FAULT LIGHTS AND CHECK THE ABS BRAKES FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 11, 2005. OWNERS MAY CONTACT AUTOCAR AT 1-877-973-3486.

Reported: 2005-04-22 (April 22, 2005)

ON CERTAIN HEAVY DUTY CLASS 8 VEHICLES FITTED WITH NEWAY AD SERIES SUSPENSIONS, THE SUSPENSION HAS TRANSVERSE BEAM CASTINGS THAT MAY FRACTURE UNDER NORMAL LOADS. IF A CASTING BREAKS WHEN THE VEHICLE IS TRAVELING ON A ROADWAY THERE IS THE POTENTIAL FOR PIECES OF THE CASTING TO BECOME PROJECTILES AND THE SUSPENSION'S TRANSVERSE BEAM MAY DROP DOWN LOW ENOUGH TO CONTACT THE ROAD SURFACE.

Consequence: THIS WILL CAUSE SPARKS THAT COULD POTENTIALLY IGNITE AND CAUSE A FIRE.

Remedy: DEALERS WILL INSPECT AND REPLACE THE DEFECTIVE TRANSVERSE BEAM ASSEMBLIES FREE OF CHARGE. THE RECALL BEGAN ON APRIL 1, 2005. OWNERS MAY CONTACT AUTOCAR AT 765-489-5499.

Reported: 2005-06-21 (June 21, 2005)

ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS, THE BACKUP ALARM MOTION SENSOR MAY NOT HAVE BEEN INSTALLED CORRECTLY AND MAY NOT SENSE WHEN THE VEHICLE MOVERS BACKWARDS UNDER ANY CIRCUMSTANCES.

Consequence: THE VEHICLE MAY ROLL BACKWARDS WITHOUT THE BACKUP ALARM SOUNDING WITH THE RISK OF RUNNING OVER OR CRUSHING A PERSON STANDING OR WORKING BEHIND THE VEHICLE.

Remedy: DEALERS WILL REPOSITION THE MOTION SENSOR IN RELATION TO THE MAGNETS THAT ROTATE WHEN THE VEHICLE MOVES. THE RECALL BEGAN ON OCTOBER 19, 2004. OWNERS MAY CONTACT AUTOCAR AT 1-877-973-3486.

Reported: 2006-02-09 (February 9, 2006)

ON CERTAIN HEAVY DUTY TRUCKS, EXPOSED 12V TERMINALS ON THE BATTERY DISCONNECT SWITCH ARE IN CLOSE PROXIMITY TO A HINGED METAL LATCH ON THE BATTERY BOX LID. WHEN LATCHING OR UN-LATCHING THE BATTERY BOX LID, IT IS POSSIBLE THAT A PERSON WEARING METAL JEWELRY (LIKE A WATCH OR FINGER RING) MIGHT CONNECT THE GROUNDED, METAL LATCH TO THE EXPOSED POSITIVE TERMINALS ON THE BATTERY DISCONNECT SWITCH THROUGH SUCH JEWELRY.

Consequence: GROUNDING AS A RESULT OF THE CONTACT DESCRIBED ABOVE COULD PRODUCE HEAT AND COULD CAUSE BURNS TO SKIN THAT IS IN CONTACT WITH METAL JEWELRY.

Remedy: DEALERS WILL RELOCATE THE SWITCH TO A POSITION FURTHER AWAY FROM THE METAL CATCH AND INSTALL ISOLATING PROTECTORS OVER THE BATTERY DISCONNECT SWITCH TERMINALS. THE RECALL IS BEGAN ON FEBRUARY 20, 2006. OWNERS MAY CONTACT AUTOCAR AT 1-765-489-5499.

Reported: 2006-05-18 (May 18, 2006)

ON CERTAIN HEAVY-DUTY CLASS 8 VEHICLES, THE TABS ON SOME OF THE LIFT AXLE SPINDLE NUTS MAY HAVE BEEN BROKEN DURING ASSEMBLY. WHEN IN PLACE, THE TABS ON THE NUTS PREVENT THE NUTS FROM LOOSENING.

Consequence: WHEN THE TABS ARE BROKEN, THE POSSIBILITY EXISTS THAT THE NUT MIGHT SPIN OFF. IF THIS HAPPENS, THE WHEEL AND WHEEL END ASSEMBLY COULD FALL OFF, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE LIFT AXLE SPINDLE NUT. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT AUTOCAR AT 1-765-489-5499.