2003 Mack CH Problems, Complaints & Recalls

Problem: On certain trucks equipped with aset ac model engines, the engine as configured with an external exhaust gas recirculation system makes servicing the fuel injection lines difficult when using traditional tools. Therefore, it is possible for fuel leaks to develop when removing and installing the fuel injection lines.

Risk: A leak in the fuel injection line may spray fuel on the hot surfaces of the exhaust gas recirculation system, which could result in an engine fire.

Fix: Dealers will replace the fuel injection lines free of charge. Note: this recall supersedes a previous campaign conducted in 2006 (please see 06v392). The recall began on september 11, 2007, with subsequent mailings every six weeks until april 2008. Owners may contact mack at 800-528-6586.

Problem: On certain trucks, a leak in the aset ac fuel injection line may spray fuel on the exhaust gas recirculation pipes that carry hot exhaust gases .

Risk: This could potentially result in an engine fire.

Fix: Mack has issued a stop work on this campaign under further notice (2-22-2007). The remedy does not adequately address the issue on all vehicles. Mack will re-release the recall in the near future. (please see nhtsa no. 07v159/mack recall no. Sco323 for vehicles that have had this repair already performed.) this recall has been superseded (please see 07v401/sc0324).

Problem: On certain heavy duty class 8 diesel trucks equipped with aset ac engines, the location of the fuel inlet hose may result in overheating or abrasion of the hose, which may lead to a premature failure.

Risk: If the hose fails, fuel can be sprayed on the exhaust manifold, which could potentially lead to an engine compartment fire.

Fix: Dealers will repair and replace the fuel inlet hose free of charge. The recall began on february 14, 2005. Due to some quality and supply issues with parts to support this safety recall, owners may have been informed during april 2005,that the safety recall was on hold. These issues have now been resolved. For owners who have not had their vehicle(s) repaired, contact a mack parts and service center immediately to schedule an appointment to have your vehicle(s) repaired. Owners may contact mack trucks at 610-709-2131.

Problem: On certain truck chassis, the steering gear mounting bolts were made of inconsistent bolt material, which has led to bolt failures. This inconsistent bolt material condition could result in a failure of a steering gear mounting bolts. The steering gear is mounted to the vehicle's frame with three bolts.

Risk: Failure of two of the three bolts could result in the loss of steering, which could result in loss of vehicle control and crash without warning.

Fix: Dealers will inspect vehicles. New steering gear mounting bolts will be installed. The recall began october 2004. Owners should contact mack at 1-610-709-3337.

Problem: On certain chassis built with lng engines, the nexgen lng tank's primary and secondary relief valves could fail to open and relieve tank pressure.

Risk: This could cause ice buildup on the discharge side of the primary and secondary pressure system allowing the relief system to freeze and become blocked resulting in over pressurization of the lng tanks creating the risk of catastrophic tank rupture which could cause serious injury or death.

Fix: Dealers will retrofit the lng tanks with a new primary relief valve pipe away tube and a new ventilated shroud. The recall began april 6, 2004. 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 mack at 1-610-709-3337.

Problem: On certain chassis equipped with dana steering axle assemblies. These axles are built with an integral knuckle and steering arm. The steering arm could have longitudinal cracks.

Risk: The ball stud could become loose, causing loss of steering control which could result in a crash.

Fix: Dealers will inspect the integral knuckle and steer arm and replace if necessary. Owner notification began on january 16, 2004. 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 mack at 1-610-709-3337.

Problem: Certain heavy duty vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 121, "air brake systems." improper seating of the check valve retainer in the brass fitting housing has occurred. It is possible for the air brake system pressure to push the check valve internal parts into the primary system reservoir and a vehicle operator would not know that this has happened.

Risk: In this condition, the vehicle would not meet the emergency requirements of the standard.

Fix: Dealers will replace the check valve. Owner notification began november 26, 2003. Owners should contact mack at 1-610-709-3337.