2004 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 TRUCKS, THE CYLINDER HEAD IDLER GEAR BUSHING MAY HAVE BEEN IMPROPERLY MACHINED, CAUSING EXCESSIVE STRESS ON THE CYLINDER HEAD GEAR SHAFT.

Consequence

CONTINUED OPERATION IN THIS CONDITION COULD CAUSE THE IDLER GEAR SHAFT FLANGE TO BREAK AND GENERATE ABNORMAL ENGINE NOISE AND/OR ENGINE OIL LEAKS. IN THE WORST CASE, THE ENGINE COULD STALL AND WOULD NOT RESTART, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL MEASURE THE INSIDE DIAMETER OF THE CYLINDER HEAD IDLER GEAR BUSHING. IF THE BUSHING IS OUT OF SPECIFICATION, DEALERS WILL REPLACE THE IDLER GEAR BUSHING, IDLER GEAR SHAFT, AND IDLER GEAR ASSEMBLY FREE OF CHARGE. 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 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.