On certain vehicles, a lubrication hole within the 6-speed manual transmission transfer case was not drilled during machining process. This could lead to premature wear or breakage of third gear. If the third gear breaks while the vehicle is in motion a loss of power to the drive wheels will occur, which may result in a vehicle crash.
Safety Risk
No risk description available.
Remedy
Dealers will drill an oil lubrication hole in the transfer case and, if necessary, replace internal components.
On certain motorcycles, the chain roll pin roller (between the fuel tank and the top chain run) could break. If fragments become lodged between the chain and pinion, it could cause the rear wheel to lock, which could result in a crash.
Safety Risk
No risk description available.
Remedy
Dealers will replace the bracket of the top chain take-up roller.
On certain vehicles, the gearshift lever stud assembly may not have received adequate tighten torque during vehicle assembly. If the gearshift lever cable or stud assembly becomes loose, it may not be possible to engage, disengage, or shift gears. This could result in a crash causing property damage, personal injury, or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and torque the gearshift lever stud assembly to the correct specification.
On certain vehicles, a crack can occur in the Continuously Variable Transmission (CVT) cooler hose, resulting in a transmission fluid leakage and illumination of the Malfunction Indicator Lamp (MIL). A transmission fluid leak, in the presence of an ignition source, could result in an engine compartment fire causing property damage or personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the cooler hose.
Certain motorcycles, may have a defective chain and sprocket set. The problems are due to fluctuations in the manufacturing process of the drive chains. If the drive chain snaps the drive fails, which can lead to safety-critical riding situations. Under worst-case conditions the rear wheel might lock up if the drive chain snaps and becomes trapped between the wheel and the frame. This could lead to a loss of vehicle control and result in a crash causing property damage, personal injury or death.
On certain four-wheel drive vehicles, the joint portion of the front driveshaft may contain small cracks. These cracks may eventually lead to a failure, resulting in separation of the front driveshaft. If the driveshaft failed while the vehicle was moving, a loud noise would be heard. If the vehicle were in 2WD mode, the driveshaft would come to rest on the frame cross-member, and the vehicle could be operated normally. The driveshaft would not come in contact with brake, steering or fuel system components, therefore the risk of a crash is considered minimal.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the vehicle and replace the front driveshaft if necessary.
On certain four wheel drive vehicles, the joint portion of the drive shaft may include a component that developed cracks during the manufacturing process. These cracks may eventually lead to separation of the drive shaft resulting in the shaft contacting the road. This situation could lead to a loss of control causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the vehicle and replace the front drive shaft if necessary.
On certain vehicles equipped with an automatic transmission, operating under rigorous off-road conditions could cause the transmission fluid temperature to elevate to the point of causing transmission failure. Should the transmission fluid boil over, it may come into contact with a hot engine or exhaust component and cause a fire which could result in property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will install a "HOTOIL" message in the instrument cluster and a chime to indicate elevated transmission fluid temperature.
On certain Audi A3, TT, TT Roadster, and Volkswagen EOS, Golf wagon, GTI, Jetta and Jetta wagon equipped with a Direct-Shift Gearbox (DSG), the wiring harness of a temperature sensor in the DSG may have connector wires that were insufficiently crimped during assembly. As such, the temperature sensor could falsely detect a high gearbox oil temperature, causing the transmission to abruptly shift to the Neutral position. A loss of propulsion, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will reprogram the transmission control module with updated software..
On certain Dodge Ram heavy duty pickup trucks equipped with a manual transmission and the optional power adjustable pedal package, the clutch pedal connecting rod to the clutch master cylinder may separate. This may not allow disengagement of the clutch when the pedal is depressed, which could result in unintended vehicle movement, increased stopping distance and engine stalling. Such an occurrence could result in a vehicle crash causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the clutch master cylinder hydraulic system.
On certain vehicles, miss-alignment of the joint between the front differential coupling and the front propeller shaft can cause undue wear to the splines within the coupling. Over time, this could cause the splines to shear, resulting in a loss of drive. Loss of propulsion, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the propeller shaft with an updated version.
On certain motorcycles, the chain sprocket fasteners may become loose which, in the worst case, could cause a loss of vehicle propulsion. Lost propulsion, in conjunction with traffic and road conditions, and the rider's reactions, could increase the risk of a crash.
Safety Risk
No risk description available.
Remedy
Dealers will tighten the sprocket fasteners to specs.
On certain M3 vehicles equipped with the multistage downshifting of the double clutch gearbox, during some cases involving rapid vehicle deceleration, the transmission software may perform a multistage downshift. In this situation the clutch is open for a approximately 200msec. When this occurs, positive gear engagement is interrupted. In conjunction with the engine's over run fuel cut-off at low speed, there is a possibility for the engine to stall. Loss of propulsion, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
Safety Risk
No risk description available.
Remedy
Dealers will re-program the Engine Electronic Control Module.
Certain All-Wheel Drive (AWD) vehicles may have been assembled with an incorrectly manufactured transfer case that could cause early failure of drive chain. If the chain breaks, shifting the transmission to "Park" may not keep the vehicle stationary. If the vehicle is parked on an incline or bumped, it may roll and strike a person , an object or vehicle without warning and cause personal injury.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the transfer case code and, if necessary, replace the transfer case.
On certain Cutaway vans, the transmission may self-engage into first gear while the vehicle is traveling at highway speeds, thereby causing transmission damage to certain gears. Should this occur at speeds beyond 130 km/h, the engine may shut down (and be able to be restarted with limited operating capability). However, in some cases, the transmission will no longer function in any gear. This could cause the vehicle to lose propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
Safety Risk
No risk description available.
Remedy
Dealers will reprogram the Transmission Control Module (TCM) and the Engine Control Module (ECM).
Certain motorcycles may experience fifth gear galling on the clutch shaft due to lack of lubrication, which could allow the gear to seize to the shaft, resulting in rear wheel lock-up. This, in conjunction with traffic and road conditions, and the rider's reactions, could increase the risk of a crash, causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will add an oil jet to the clutch shaft in order to increase lubrication to the fifth gear journal.
On certain vehicles equipped with an F1 manual transmission, the clutch sensor may malfunction under normal operating conditions, which could inhibit the proper function of the clutch assembly, making shifting of the gears very difficult, and potentially rendering the vehicle inoperable. In conjunction with traffic and road conditions, and the driver's reactions, this could increase the risk of a crash, causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the clutch sensor with an updated version.
On certain vans, club wagons, cutaway's and stripped chassis', the driveshaft may have been manufactured with a slip yoke that has cracks. Over time, these cracks may propagate, allowing the slip yoke to break while the vehicle is in motion, causing the driveshaft to detach from the vehicle. Separation of the driveshaft would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. In addition, once separated from the vehicle the driveshaft could cause vehicle damage or damage to other vehicles and property, and could potentially result in personal injury or death to bystanders.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the driveshaft.
On certain vehicles, the drive axle differential seal may leak (note that all-wheel drive vehicles have two seals). Reduced lubrication may cause the differential to become noisier. Continued use may cause damage to bearings and other differential components. Three conditions could occur: 1). When the vehicle is stopped and shifted to reverse, the differential may jam and prevent vehicle movement. 2). the damage can cause drag that will feel like the parking brake is applied; or 3) the differential could jam and lock the drive wheels while the vehicle is underway. Should the latter occur, it could result in a loss of vehicle control and a crash, causing injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the drive axle differential seal(s).
On certain four wheel drive vehicles, the rear driveshaft slip yoke may have received improper heat treatment during the manufacturing process. Insufficient hardness may allow the slip yoke to break, causing the propeller shaft to separate at the joint and come into contact with the road surface or the fuel tank. A fuel leak, in the presence of an ignition source, could result in a vehicle fire. Loss of the rear driveshaft would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash, causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if required, replace the propeller shaft.
