Turbocharger Faults
Wires within the smart remote actuator (SRA) connector located on the right-hand side of Mack MP7, MP8 and MP10 engines below the turbocharger are subject to vibration during engine operation.
This vibration can result in terminal fretting which produces very fine dust particles and can be seen as a fine green dust inside the connector. When these particles migrate between the female and male pin connectors, intermittent contact problems will result and be made evident by SID 27 and PSID 232 fault codes (see Figure 1).
Installing a connector back shell (Part No. 3985620) on the back of the male (mounting bracket side) SRA connector and securing the harness wires by installing a tie wrap around the fabric cover will correct this condition by dampening the vibration to reduce terminal fretting.
If you encounter multiple instances of logged SID 27 and PSID 232 fault codes, install the connector back shell and secure the wires as follows:
- Disconnect the SRA connector (the bottom connector on the mounting bracket) and then unscrew the bulkhead nut to remove the connector body from the mounting bracket.
- Clean both the SRA side and engine harness side of the connector with a high-quality electrical contact cleaner.
- Install the plastic back shell (Part No. 3985620) over the back of the connector (male side), making sure the fabric cover extends inside the shell.
- Secure the wires by installing a tie wrap (Part No. 948211) around the fabric cover immediately behind the plastic back shell (within 10mm of the rear of the shell).
- Reinstall the connector body to the mounting bracket and then reconnect the connector. Road test the vehicle and recheck the system for faults.
Unauthorized Axle Camber Modifications
Hendrickson does not approve of and strongly warns against using equipment to bend or otherwise modify its Steertek fabricated axles in order to change camber. The company says that all Steertek axles are designed to maintain a non-adjustable camber specification. Any bending or modification of the axle may reduce its strength and structural integrity.
Do not bend, weld or modify Steertek axles without authorization from Hendrickson. Steertek technical publications contain the following warning: Axle camber is not adjustable. Do not change the axle camber angle or bend the axle beam. Bending the axle beam to change the camber angle will damage the axle and reduce axle strength and will void Hendrickson’s warranty. A bent axle beam can cause loss of vehicle control, possibly causing personal injury or property damage.
In addition, Steertek axles currently are equipped with a decal also warning that unauthorized modifications can cause cracks or other axle structural damage and result in loss of vehicle control.
Safety Recalls/ The National Highway Traffic Safety Administration (NHTSA) has issued the following recalls:
- On 338 model year 2009 Mack MRU and LEU heavy-duty trucks manufactured from August 20 through November 26, 2008, and equipped with certain Haldex quick release valves (QRV), the rubber diaphragm inside the QRV may experience delamination resulting in significant levels of air pressure leakage past and/or through the diaphragm, or the development of a bubble in the diaphragm which may trap air pressure in the valve and not allow the service brakes to release. Malfunction of the air-brake system could result in a vehicle crash.
- On 43 Great Dane model year 2009 semi-trailer converter dollies, Model DLY-0022-00099, manufactured for FedEx Ground between July 16 and August 13, 2008, equipped with certain Haldex quick release valves (QRV), the rubber diaphragm inside the QRV may experience delamination resulting in significant levels of air pressure leakage past and/or through the diaphragm, or the development of a bubble in the diaphragm which may trap air pressure in the valve and not allow the service brakes to release. Malfunction of the air-brake system could result in a vehicle crash.
- The engine cooling fan on 17,614 model year 2008-2009 Volvo S80, V70 and XC70 vehicles may stop working because of a software programming error in the fan control module. Depending on driving conditions, the customer may experience reduced air conditioning performance and/or rapid increase in engine coolant temperature. This situation may result in loss of cooling system function and engine failure. The driver may not have sufficient time to react to the warning light(s) or the text message in the instrument panel, increasing the risk of a crash.
- A new forward cab crossmember design on three model year 2009-2010 Western Star 4900 trucks built with DD15 engines have reduced clearance for cab mounted battery disconnect switch power cables on standard cab height vehicles. During cab articulation the new crossmember may pinch power cables against the cab. Cables that become pinched between the cab and forward cab crossmember could short to ground and potentially overheat resulting in injury to vehicle occupants. The cables need to be reinstalled in a new, safe location.
- Thirteen model year 2009 Kenworth T2000 vehicles may fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 106, “Brake Hoses.” The air tube expander fitting used between the air tube inlet and dash air gauges for the trailer do not meet the burst pressure requirements. This can result in brake hose rupture, air pressure loss and compromised vehicle braking which could result in a crash without warning.
- The brake spider mounting fasteners attaching the brake spider to the front steer axle flange on nine Kenworth model year 2009 T800S vehicles equipped with Dana front axles may have received insufficient torque during the installation process. The insufficient torque may allow the brake spider fasteners and brake spider to become loose. This can allow the fasteners to shear and fall either onto the roadway or into the drum brake assembly, potentially allowing the brake to bind and causing increased stopping distance and a crash could occur. Inspect and replace the brake spider mounting fasteners and torque them properly, as well as review the brake spider and steer axle flange holes for signs of vibration and fatigue and replace if necessary.
- The axle beam on 10,300 model year 2004 and 2005 Mack CL, CV, DM, LE and RB and model year 2004 RD heavy trucks manufactured from October 1, 2003, through September 30, 2004, equipped with axle beams manufactured by Bharat Forge may have transverse shear lines on the bottom of the axle from the trimming process. These lines, if present, can promote initiation of cracks, which over time may possibly lead to axle beam failure and a vehicle crash can occur.
- Increased brake excitation may be found on 3,423 Kenworth model year 2004-2009 T2000, T800, T600, W900 and T660 vehicles in a certain vehicle configuration which includes Bendix drum brakes, wide base low profile single tires and an AG400 or AG460 rear suspension. Brake excitation can cause fatigue and cracking of brake assembly components. Cracking can cause a complete fracture of the cam tube, which could increase stopping distance and decrease parking brake hold capability. Inspect the rear axle brakes assembly, replace cracked rear axle brakes assembly components where required and install cam tube support brackets on all rear axle wheel ends.
- Approximately 900 Cummins ISB CM2150, ISC CM2150, ISL CM2150, ISM CM876 and ISX CM871 model diesel engines installed as original equipment on emergency vehicles may be designed with a hard-wired, dash-mounted switch that enables the vehicle operator to inhibit aftertreatment diesel particulate filter regeneration in environments where the operator feels it may be unsafe for elevated exhaust temperatures. Because of an issue with the logic in the ECM software in these engines, the switch may not function correctly, leading the operator to believe that the switch is in inhibit mode when it is not. This condition will allow hot exhaust gases to exit the vehicle tailpipe, increasing the risk of melting or burning of nearby surfaces, or a fire.
· There is a mislocation of a circumferential weld on 3,056 model year 2009 Kenworth and Peterbilt vehicles equipped with TRW steering shafts. This mislocated weld may allow the splined tube and non-splined tube to rotate relative to one another during a low-speed, high-torque turn, possibly resulting in a separation of the two tubes. A separation of the splined and non-splined tubes could cause a loss of steering control and increase the risk of a crash.
