2001 Mitsubishi Fuso FE640 problems

Defect

MITSUBISHI FUSO TRUCK OF AMERICA (MFTA) IS RECALLING 156 HALOGEN SEALED BEAM HIGH BEAM HEADLAMP ASSEMBLIES SOLD BETWEEN OCTOBER 24, 2007 AND DECEMBER 2, 2008 FOR USE AS REPLACEMENT EQUIPMENT FOR CERTAIN MITSUBISHI FUSO TRUCKS. THESE LAMPS FAIL TO CONFORM TO THE SAE STANDARDS OR RECOMMENDED PRACTICES REFERENCED IN TABLE I OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."

Consequence

THE PURPOSE OF THIS STANDARD IS TO REDUCE DEATHS AND INJURIES FROM MOTOR VEHICLE CRASHES BY PROVIDING ADEQUATE ILLUMINATION OF THE ROADWAY.

Remedy

MFTA WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 15, 2009. OWNERS MAY CONTACT MFTA AT 1-856-467-4500.

Defect

MITSUBISHI FUSO IS RECALLING 15,549 MY 1999-2004 FE639, FE649, AND FG639 TRUCKS; MY 2001-2004 FE640, AND MY 2003-2004 FH210 TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS. NORMAL HEAT EMANATING FROM THE EXHAUST PIPE MAY CAUSE THE AUTOMATIC TRANSMISSION SHIFT LINKAGE TO DEFORM. THE EFFORT REQUIRED TO OPERATE THE AUTOMATIC TRANSMISSION SHIFT CONTROL LEVER MAY INCREASE IF THE LINKAGE BINDS DUE TO THE DEFORMATION.

Consequence

THE SHIFT CONTROL LEVER MAY BECOME INOPERATIVE, OR THE PHYSICAL SHIFT LEVER POSITION ON THE SHIFT LEVER HOUSING GEAR INDICATOR MAY NOT MATCH THE ACTUAL GEAR SELECTION AT THE TRANSMISSION.

Remedy

DEALERS WILL INSTALL A MODIFIED AUTOMATIC TRANSMISSION SHIFT CONTROL LEVER ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 6, 2008. OWNERS MAY CONTACT MITSUBISHI FUSO AT 1-856-467-4500.

Defect

ON CERTAIN TRUCKS, THE CYLINDER HEAD IDLER GEAR BUSHING MAY HAVE BEEN IMPROPERLY MACHINED, CAUSING EXCESSIVE STRESS ON THE CYLINDER HEAD IDLER GEAR SHAFT. CONTINUED OPERATING IN THIS CONDITION COULD CAUSE THE IDLER GEAR SHAFT FLANGE TO BREAK AND GENERATE ABNORMAL ENGINE NOISE OR ENGINE OIL LEAKS.

Consequence

THE ENGINE COULD STALL AND WOULD NOT RESTART INCREASING THE RISK OF A CRASH.

Remedy

ON VEHICLES WITH LESS THAN 15,000 MILES, IF THE IDLER GEAR AND BUSHING ASSEMBLY, IDLER GEAR SHAFT AND BOLT WILL BE REPLACED. IF THE MILEAGE IS MORE THAN 15,000 MILES, THE INSIDE DIAMETER OF THE IDLER GEAR BUSHING WILL BE MEASURED AND IF THE BUSHING MEASURES MORE THAN 32.043MM (1.262"), THE IDLER GEAR AND BUSHING ASSEMBLY, IDLER GEAR SHAFT AND BOLT WILL BE REPLACED. THE RECALL BEGAN ON AUGUST 13, 2007. OWNERS MAY CONTACT MITSUBISHI FUSO AT 1-856-467-4500.

Defect

ON CERTAIN MEDIUM DUTY TRUCKS, THE CYLINDER HEAD IDLER GEAR SHAFT BOLT MAY HAVE BEEN INSUFFICIENTLY TIGHTENED DURING INITIAL ASSEMBLY. CONTINUED OPERATION IN THIS CONDITION COULD CAUSE THE BOLT TO LOOSEN, RESULTING IN ABNORMAL NOISE FROM IMPROPER GEAR ALIGNMENT.

Consequence

THE BOLT COULD BREAK, CAUSING THE ENGINE TO STALL AND NOT RESTART, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL CHECK THE IDLER SHAFT BOLT. IF THE BOLT CANNOT BE REMOVED BY HAND, A MODIFIED IDLER SHAFT BOLT WILL BE INSTALLED. IF THE BOLT IS LOOSE ENOUGH TO BE REMOVED BY HAND, A NEW IDLER GEAR, IDLER SHAFT, AND A MODIFIED IDLER SHAFT BOLT WILL BE INSTALLED. THE RECALL BEGAN ON DECEMBER 20, 2005. OWNERS MAY CONTACT MITSUBISHI FUSO AT 1-856-467-4500.

Defect

ON CERTAIN MEDIUM DUTY TRUCKS, RUST BUILD-UP ON THE AUTOMATIC TRANSMISSION (A/T) SHIFT LINKAGE MAY CAUSE THE LINKAGE TO BIND. RUST BUILD-UP IS ACCELERATED IN GEOGRAPHIC LOCATIONS THAT ARE SITUATED NEAR LARGE BODIES OF SALT WATER, OR IN REGIONS WITH HEAVY SNOW/ICE MELTING COMPOUND USAGE IN WINTER MONTHS.

Consequence

THE EFFORT REQUIRED TO OPERATE THE A/T SHIFT CONTROL LEVER MAY INCREASE IF THE LINKAGE BINDS DUE TO RUST BUILD-UP. THE SHIFT CONTROL LEVER MAY BECOME INOPERATIVE, OR THE PHYSICAL SHIFT LEVER POSITION ON THE SHIFT LEVER HOUSING GEAR INDICATOR MAY NOT MATCH THE ACTUAL GEAR SELECTION AT THE TRANSMISSION.

Remedy

DEALERS WILL INSTALL A MODIFIED A/T SHIFT CONTROL LEVER ASSEMBLY. THE RECALL BEGAN ON SEPTEMBER 26, 2005. OWNERS MAY CONTACT MITSUBISHI FUSO AT 1-856-467-4500.

Defect

ON CERTAIN MEDIUM DUTY TRUCKS, THE REAR ENGINE SUPPORT BRACKET IS COMPOSED OF MATERIALS OF INSUFFICIENT STRENGTH. NORMAL VEHICLE VIBRATIONS MAY CAUSE THE BRACKET TO CRACK.

Consequence

IF THE VEHICLE IS CONTINUALLY OPERATED IN THIS CONDITION, THE BRACKET MAY BREAK APART, CAUSING THE TRANSMISSION TO DROP OUT OF ALIGNMENT WITH THE DRIVE TRAIN.

Remedy

DEALERS WILL INSTALL A MODIFIED REAR ENGINE SUPPORT BRACKET. THE RECALL BEGAN ON SEPTEMBER 26, 2005. OWNERS SHOULD CONTACT MITSUBISHI FUSO AT 1-856-467-4500.

Defect

ON CERTAIN TRUCKS, THE CABLE END OF THE PARKING BRAKE CABLE, WHERE IT ATTACHES TO THE PARKING BRAKE LEVER, IS DESIGNED IMPROPERLY. REPEATED NORMAL PARKING BRAKE OPERATION MAY CAUSE THE CABLE END TO BECOME IMPROPERLY SEATED IN THE PARKING BRAKE LEVER GROOVE.

Consequence

IN THIS CONDITION, THE PARKING BRAKE CABLE MAY BEND AND BREAK DUE TO FATIGUE. THE PARKING BRAKE MAY BECOME INOPERATIVE AND THE TRUCK MAY ROLL AND CAUSE A CRASH, PROPERTY AND PERSONAL INJURIES.

Remedy

DEALERS WILL INSPECT THE PARKING BRAKE CABLE FOR BENDING OR DAMAGE AT THE CABLE END AND INSTALL A MODIFIED PARKING BRAKE CABLE ASSEMBLY IF THE CABLE IS BENT OR DAMAGED AT THE CABLE END. IF NO BENDING OR DAMAGE EXISTS, DEALERS WILL INSTALL A CABLE RETAINER ON THE CABLE END OF THE PARKING BRAKE CABLE. THE RECALL BEGAN ON JANUARY 13, 2005. OWNERS SHOULD CONTACT MITSUBISHI FUSO AT 1-877-711-0707.

Defect

ON CERTAIN TRUCKS, THE RUBBER PORTION OF THE FUEL INJECTION PIPE CLAMPS COULD DETERIORATE. NORMAL VEHICLE OPERATION COULD CAUSE THE DETERIORATED CLAMP TO LOOSEN AND DRIP.

Consequence

IF THIS CONDITION OCCURS IN THE AREA OF THE FUEL INJECTION PUMP, THE ENGINE STARTER COULD SHORT CIRCUIT IF THE CLAMP DROPS ONTO THE STARTER TERMINAL. THIS COULD PREVENT THE ENGINE FROM STARTING. EXCESSIVE HEAT FROM THE SHORT CIRCUIT COULD CAUSE A FIRE.

Remedy

DEALERS WILL REMOVE EACH CLAMP AND INSPECT FOR RUBBER DETERIORATION AND WILL REPLACE THE CLAMP IF THE RUBBER DETERIORATION IS EVIDENT. DEALERS WILL REPLACE THE ATTACHING HARDWARE AND APPLY ADHESIVE TO PREVENT THE BOLTS/NUTS FROM LOOSENING AND INSPECT FOR A RUBBER CAP ON THE STARTER MOTOR'S TERMINAL AND INSTALL A CAP IF ONE IS NOT PRESENT TO PREVENT A SHORT CIRCUIT. THE RECALL BEGAN ON JANUARY 13, 2005. OWNERS SHOULD CONTACT MITSUBISHI FUSO AT 1-877-711-0707.

Defect

ON SOME HEAVY DUTY TRUCKS, THE VACUUM PUMP SHAFT BREAKS DUE TO INSUFFICIENT HEAT TREATMENT.

Consequence

IF THE SHAFT BREAKS, BRAKING DISTANCE WOULD BE EXTENDED DUE TO THE LACK OF BRAKE BOOSTER FUNCTION, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL INSPECT AND REPLACE THE VACUUM PUMP SHAFT ASSEMBLY. OWNER NOTIFICATION BEGAN FEBRUARY 15, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT MITSUBISHI FUSO TRUCK AT 1-856-467-4500.