2004 Freightliner FLD: complaints, problems and recalls

AS A MECHANICAL ENGINEER AND ACCIDENT RECONSTRUCTIONIST I WAS ASKED TO EXAMINE THE FRONT AXLE OF A LATE MODEL FREIGHTLINER TRUCK-TRACTOR THAT HAD BEEN IN A LOSS-OF-STEERING-CONTROL TYPE ACCIDENT. THE ACCIDENT RESULTED IN A TOTAL LOSS OF THE TRACTOR, THE TRAILER, THE TRAILER LOAD AND INJURY TO THE DRIVER. UPON EXAMINING THE LEFT FRONT STEERING SPINDLE I NOTICED IT HAD SEPARATED FROM THE AXLE. THE PLACE WHERE THE SPINDLE CONNECTS TO THE AXLE IS EFFECTED BY AN INTERFERENCE FIT BETWEEN A SOLID CYLINDER AND A CYLINDRICAL HOLE WITH NO OTHER MEANS OF …

Owner-reported narrative. 200,000 miles reported. Look up ODI 10119642 at NHTSA ↗

Reported: 2004-12-15 (December 15, 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.

Consequence: THIS CONDITION ALLOWS THE BOLTS USED IN THE HOLES TO BECOME DETACHED WHICH COULD RESULT IN A DRIVELINE SEPARATION. DRIVELINE SEPARATION COULD RESULT IN A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE SUSPECT MALE SHAFT YOKES. THE RECALL BEGAN ON APRIL 4, 2005. OWNERS SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.

Reported: 2004-12-15 (December 15, 2004)

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

Consequence: LOOSE BRAKE PEDAL PUSHROD JAM NUTS COULD CAUSE LOSS OF CONTROL OF THE VEHICLE AND A CRASH MAY OCCUR.

Remedy: DEALERS WILL ADJUST THE PEDAL PUSHROD. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.

Reported: 2005-06-14 (June 14, 2005)

ON CERTAIN TRUCKS EQUIPPED WITH 3RD GENERATION CONMET ALUMINUM WHEELS, THE DRUM MOUNTING FLANGE ON THE CONMET TRUTURN BRAKE DRUM MAY HAVE BEEN MANUFACTURED WITH A TAPER FROM THE PILOT HOLE TO THE BARREL OF THE DRUM.

Consequence: THIS TAPER MAY CAUSE CRACKING OR FRACTURES OF THE FRONT HUB. THIS COULD CAUSE A CRASH WITHOUT PRIOR WARNING.

Remedy: AFTER FURTHER INVESTIGATION AND TESTING, FREIGHTLINER HAS REVISED THE POPULATION AND THE REMEDY (DECEMBER 22, 2005). THEREFORE, THE RECALL BEGAN ON MARCH 15, 2006. OWNERS MAY CONTACT FREIGHTLINER AT 1-800-547-0712.

Reported: 2005-09-13 (September 13, 2005)

ON CERTAIN TRUCK AND MOTOR HOME CHASSIS EQUIPPED WITH I-SHAFTS SUPPLIED BY ZF HEAVY DUTY STEERING, THERE IS A POTENTIAL FOR A FAILURE OF THE FORK/SHAFT CONNECTION.

Consequence: IF THIS OCCURS, THE VEHICLE COULD SUFFER A LOSS OF STEERING ABILITY, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT AND ATTACH A TENSION COLLAR TO THE STEERING SHAFT TO SECURE THE CONNECTION TO THE YOKE. THE RECALL BEGAN ON NOVEMBER 16, 2005. OWNERS MAY CONTACT FREIGHTLINER AT 1-800-547-0712.

Reported: 2009-09-23 (September 23, 2009)

DAIMLER TRUCKS IS RECALLING MODEL YEAR 2004-2010 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINE. THE VARIABLE VALVE ACTUATION OIL LINE MAY RUB AGAINST THE P-CLIPS RETAINING THE OIL LINE, CAUSING AN OIL LEAK.

Consequence: AN OIL LEAK MAY RESULT IN A FIRE.

Remedy: DAIMLER TRUCKS IS WORKING WITH CATERPILLAR TO REMEDY THESE VEHICLES. PLEASE SEE CATERPILLAR'S DEFECT REPORT 09E-020. CATERPILLAR WILL INSPECT AND REPAIR THE NECESSARY COMPONENTS FREE OF CHARGE. THE RECALL BEGAN ON MAY 5, 2009. OWNERS MAY CONTACT CATERPILLAR TOLL-FREE AT 1-800-447-4986 OR DAIMLER TRUCKS AT 1-800-547-0712.

Reported: 2011-09-16 (September 16, 2011)

DAIMLER TRUCKS IS RECALLING CERTAIN MODEL YEAR 2004 THROUGH 2008 HEAVY TRUCKS MANUFACTURED FROM JULY 11, 2003, THROUGH SEPTEMBER 28, 2007, EQUIPPED WITH EPA04 MODEL MBE4000 ENGINES BUILT WITH PLASTIC LOW PRESSURE FUEL LINES AND FUEL FILTERS MOUNTED NEAR THE CENTER OF THE ENGINE ON THE LEFT-HAND SIDE. THE PLASTIC LOW PRESSURE FUEL LINE BETWEEN ENGINE MOUNTED FUEL FILTER AND ENGINE BLOCK MAY DEVELOP A SUBSTANTIAL DIESEL FUEL LEAK.

Consequence: THIS COULD CREATE A ROAD HAZARD INCREASING THE RISK OF A CRASH. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DAIMLER TRUCKS WILL NOTIFY OWNERS AND THE REMEDY WILL BE PERFORMED BY DETROIT DIESEL CORPORATION AUTHORIZED REPAIR FACILITIES. VEHICLES WILL BE INSPECTED AND THE PLASTIC LOW PRESSURE FUEL LINE WILL BE REPLACED WITH A STEEL LOW PRESSURE FUEL LINE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. AN INTERIM LETTER WAS MAILED TO OWNERS ON OCTOBER 28, 2011. THE SAFETY RECALL BEGAN ON FEBRUARY 21, 2012. OWNERS MAY CONTACT DAIMLER TRUCKS AT 1-800-547-0712.