1994 International Harvester 3600: complaints, problems and recalls

Reported: 1993-11-12 (November 12, 1993)

THE HYDRAULIC STEEL BRAKE LINES FROM THE MASTER CYLINDER TO THE FRAME FITTINGS ARE EXPERIENCING VERTICAL FLEXING WHICH CAUSES FATIGUE CRACKS AT THE FRAME END OF THE ASSEMBLY, RESULTING IN BRAKE FLUID LEAKAGE. THIS CAN OCCUR IN ONE OR BOTH OF THE STEEL BRAKE LINES. IN EITHER CASE, THE BRAKE WARNING LIGHT WILL COME ON AND THE LOW PRESSURE BUZZER WILL ACTIVATE.

Consequence: SHOULD A CRACK AND LEAKAGE DEVELOP IN ONE OF THE LINES,HALF OF THE BRAKING SYSTEM CAPABILITY COULD BE LOST, IMPAIRING THE STOPPINGABILITY OF THE VEHICLE. IF BOTH BRAKE LINES FAIL, THE ENTIRE SERVICE BRAKINGSYSTEM WILL BECOME INOPERATIVE. IN EITHER CASE, AN ACCIDENT COULD RESULT,CAUSING DAMAGE TO THE VEHICLE AND PERSONAL INJURY.

Remedy: NAVISTAR DEALERS WILL INSTALL A NEW, REDESIGNED PRIMARY AND SECONDARY BRAKE LINE FROM THE MASTER CYLINDER TO THE FRAME RAIL FITTINGS.

Reported: 1994-08-02 (August 2, 1994)

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: 1994-10-07 (October 7, 1994)

THE BASE OF THE ELECTRONIC ACCELERATOR PEDAL IS MADE OF DIE CAST ALUMINUM. THE BASE MOUNTS DIRECTLY TO THE CAB FIREWALL. THE CAB FIREWALL IS NOT RIGID ENOUGH OR FLAT ENOUGH AT THE MOUNTING SURFACE, CAUSING STRESS ON THE ACCELERATOR BASE THAT WILL CAUSE THE MOUNTING PADS ON THE BASE OF THE PEDAL ASSEMBLY TO FAIL AND TOTALLY SEPARATE FROM THE FIREWALL.

Consequence: THIS CAN CAUSE LOSS OF SPEED CONTROL, DRIVER DISTRACTION, AND RESULT IN AN ACCIDENT.

Remedy: DEALERS WILL INSPECT THE ACCELERATOR PEDAL ASSEMBLY AND INSTALL A PLATE BETWEEN THE ACCELERATOR MOUNTING BASE AND THE FIREWALL ON THOSE UNITS WHERE THE BASE IS NOT BROKEN AND HAS NO VISIBLE SIGNS OF A CRACK. IF THE BASE IS BROKEN OR CRACKED, THE ACCELERATOR ASSEMBLY WILL BE REPLACED WITH A NEW REDESIGNED ACCELERATOR PEDAL ASSEMBLY.

Reported: 1995-09-21 (September 21, 1995)

THE FUEL HOSE TO THE FUEL FILTER IS ROUTED TOO CLOSE TO THE ALTERNATOR BELT CAUSING THE ALTERNATOR BELT TO RUB THE FUEL HOSE. THIS CAN CAUSE A FUEL LEAK.

Consequence: FUEL LEAKAGE CAN RESULT IN A VEHICLE FIRE IF AN IGNITION SOURCE IS PRESENT.

Remedy: DEALERS WILL STRAP THE FUEL HOSE TO THE CHASSIS FRAME TO INSURE A MINIMUM OF 2 1/2" CLEARANCE BETWEEN THE FUEL HOSE AND THE ALTERNATOR BELT.

Reported: 1996-09-13 (September 13, 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: 1996-11-12 (November 12, 1996)

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.