1989 Ford B700

Component: ELECTRICAL SYSTEM:12V/24V/48V BATTERY

SYSTEM: ELECTRICAL SYSTEM; BATTERY. VEHICLE DESCRIPTION: MEDIUM DUTY SCHOOL BUS CHASSIS EQUIPPED WITH HYDRAULIC BRAKES, TILT HOODS, 5.9L, 6.6L OR 7.6L DIESEL ENGINES OR 6.1L OR 7.0L GASOLINE ENGINES AND ORIGINALLY SOLD OR CURRENTLY REGISTERED IN CONNECTICUT, ILLINOIS, INDIANA, MAINE, MASSACHUSETTS, MICHIGAN, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA ,RHODE ISLAND, VERMONT, AND WISCONSIN. THE BATTERY POWER JUNCTION BLOCK MOUNTED ON THE RIGHT FENDER APRON, WHICH SERVES AS AN ELECTRICAL CONNECTION POINT FOR SEVERAL ENGINE COMPARTMENT SYSTEMS, IS SUSCEPTIBLE TO ROAD SPLASH. THE TERMINALS AT THE JUNCTION BLOCK CAN EXPERIENCE CORROSION AND CAN FRACTURE, CAUSING LOSS OF ELECTRICAL POWER AND ENGINE SHUTDOWN.

Consequence: ENGINE SHUTDOWN, LOSS OF POWER STEERING ASSIST, OR LOSS OF HYDRAULIC BRAKE BOOST CAN OCCUR WHICH MAY RESULT IN LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

Remedy: DEALERS WILL REPLACE THE JUNCTION BOX, MAIN POWER TERMINAL THE STARTER OR STARTER RELAY AND TERMINALS AT THE EXISTING JUNCTION BLOCK. THE WIRING OF THE HYDRAULIC BRAKE CIRCUIT WILL ALSO BE MODIFIED BY BYPASSING THE JUNCTION BLOCK. THE NEW TERMINALS WILL BE MADE FROM AN ALLOY MATERIAL MORE RESISTANT TO SALT CORROSION.

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Component: STEERING:RACK AND PINION

THE STEERING GEARS HAVE AN IMPROPERLY MACHINED SNAP RING GROOVE. THIS CAN CAUSE A FRACTURE OF THE SNAP RING WITH SUBSEQUENT DAMAGE TO THE RECIRCULATING BALL GUIDE TUBE. ALSO, THE O-RING SEAL IN VEHICLES BUILT AFTER FEBRUARY 1988 DOES NOT MEET SPECIFICATIONS AND IS INADEQUATE, CAUSING INTERIOR LEAKAGE AROUND THE O-RING / GLIDE RING SEAL IN THE STEERING GEAR.

Consequence: THE FRACTURE OF THE SNAP RING RESULTS IN INCREASING DETERIORATION OF THE ABILITY TO TURN THE VEHICLE TO THE RIGHT. THE DRIVER WOULD EXPERIENCE INCREASED STEERING EFFORTS OR A "CRUNCHY" FEELING AT THE STEERING WHEEL. THE INADEQUATE O-RING SEAL CAUSES MOMENTARY REDUCTIONS IN POWER STEERING ASSIST AT LOW SPEED AND CERTAIN LEFT TURN MANEUVERS. BOTH CONDITIONS RESULT IN DECREASED STEERING ABILITY.

Remedy: DEALERS WILL REBUILD THE STEERING GEAR. IF A BROKEN SNAP RING IS FOUND DURING REBUILDING, THE STEERING GEAR WILL BE REPLACED WITH A REMANUFACTURED UNIT.

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THE BRAKE LINE TO THE RIGHT FRONT WHEEL AND THE LINE TO THE REAR BRAKES WENT THROUGH A COMMON BRACKET ALONG THE FRAME. INSIDE THIS BRACKET, COMPLETELY UNDETECTABLE, THE 2 LINES HAD RUSTED... BOTH FAILED AT THE SAME TIME. I SAW THE FLUID LEAK, BUT KNEW I HAD LOST BOTH BRAKING SYSTEMS, FRONT AND REAR, SO I CONTINUED LOOKING FOR ANOTHER LEAK. TO MY SURPRISE, BOTH LINES MADE CONTACT INSIDE THIS BOLT-ON STRAP CONNECTOR AND HAD RUSTED SIMULTANEOUSLY. ALL WARNING LIGHTS AND BUZZERS WORKED PROPERLY. WHEN THE BRAKE PEDAL HIT THE FLOOR, THE POWER STEERING SYSTEM DID NOT HAVE ENOUGH RESERVE PRESSURE TO ALLOW ME TO CONTINUE TURNING. HEADING DOWNHILL AND MAKING A HARD LEFT TURN WITH VERY LITTLE CLEARANCE FROM MY HOUSE, I NEARLY HIT MY HOUSE BEFORE COMING TO A STOP. MANY YEARS OF DOUBLE-BOTTOM 160K LB. GASOLINE TANKER DRIVING AND A SOUND MECHANICAL KNOWLEDGE HASTENED MY REACTION TIME AND I FLIPPED THE EMERGENCY BRAKE LEVER AND RELEAVED THE PRESSURE FROM THE REAR SPRING BRAKES, WHICH BROUGHT ME TO A STOP. WITH BOTH FRONT AND REAR BRAKES GONE AT THE SAME TIME, AND WITH ALL BUZZERS AND LIGHTS SENDING ME WARNINGS, STILL THE EMERGENCY BRAKING SYSTEM FAILED TO APPLY THE REAR BRAKES WITHOUT MANUALLY MOVING THE PARKING BRAKE LEVER. THIS IS THE MOST SERIOUS PROBLEM I HAVE EVER INCURRED! A BUS LOAD OF CHILDREN WOULD BE IN DESPARATE DANGER IF THIS HAPPENED TO ONE OF THE MANY SIMULAR BUSES STILL TRANSPORTING CHILDREN TODAY. VISUAL INSPECTION OF THE LINES WOULD NOT SHOW THIS PROBLEM. THE BRACKET WOULD NEED TO BE PHYSICALLY REMOVED IN ORDER TO INSPECT FOR RUST. THAT DOES NOT HAPPEN! I AM REPLACING ALL LINES ON MY BUS... I NO LONGER TRUST ANY CONNECTOR UNDERNEATH THIS OTHERWISE VERY SOLID VEHICLE.

TWO OF THE BUSES WERE RECALLED BOTH ARE STILL LEAKING AFTER THE WORK HAD BEEN PERFORMED. ONE OF THE VIN # 1FDPJ75POKVA59531. *AK