2003 International 4200 problems

Defect

NAVISTAR IS RECALLING CERTAIN MODEL YEAR 2003 THROUGH 2010 INTERNATIONAL TRUCKS AND IC COMMERCIAL BUSES MANUFACTURED FROM DECEMBER 4, 2001 THROUGH DECEMBER 14, 2009 EQUIPPED WITH INTERNATIONAL VT365 ENGINES HAVING ENGINE CALIBRATION PAN2PVR0, PAN2PVR1, OR PAN2PWR. THE ENGINE NORMALLY RESPONDS TO A FAILED OPEN ACCELERATOR POSITION SENSOR CIRCUIT FAULT BY RETURNING THE ENGINE TO LOW IDLE SPEED OF 800 RPM AND DISABLING THE DRIVER'S ABILITY TO INCREASE THE ENGINE SPEED. HOWEVER IF THE OPEN CIRCUIT CORRECTS ITSELF WITHIN 30 SECONDS OF INITIATION, ENGINE SPEED COULD SUDDENLY INCREASE TO A HIGH IDLE SPEED OF 1200 RPM.

Consequence

THIS INCREASE TO HIGH IDLE SPEED MAY OCCUR WITHOUT WARNING CAUSING A SUDDEN AND UNEXPECTED SHIFT IN VEHICLE POSITION POSSIBLY RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy

NAVISTAR WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 1, 2010. OWNERS MAY CONTACT NAVISTAR AT 1-800-448-7825.

Defect

ON CERTAIN TRUCKS EQUIPPED WITH V8 ENGINES AND AIR BRAKES OR AIR OPERATED PARK BRAKES, A STAND-OFF BRACKET WAS NOT INSTALLED. THE BRACKET SUPPORTS THE COPPER AIR COMPRESSOR DISCHARGE TUBE. NORMAL VEHICLE AND ENGINE VIBRATION CAN CAUSE THE UNSUPPORTED COPPER TUBE TO FAIL AT OR NEAR THE AIR COMPRESSOR CONNECTION.

Consequence

A FAILED COMPRESSOR DISCHARGE TUBE COULD DEPLETE THE AIR SYSTEM AND MAY CAUSE THE PARKING BRAKES TO APPLY. THIS CONDITION COULD CAUSE THE VEHICLE TO SLOW DOWN OR STOP UNEXPECTEDLY AND RESULT IN A CRASH.

Remedy

DEALERS WILL INSPECT AND REPAIR THE STAND-OFF BRACKET AS NECESSARY. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING DECEMBER 2003. OWNERS SHOULD CONTACT INTERNATIONAL TRUCK AT 1-800-448-7825.

Defect

CERTAIN HEAVY DUTY TRUCKS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS." THE PRIMARY AND SECONDARY AIR SUPPLY HOSES FROM THE FOOT VALVE TO THE PRIMARY AND SECONDARY AIR TANKS WERE IMPROPERLY ROUTED AT THE TANK.

Consequence

IF THE PRIMARY AIR CIRCUIT IS DAMAGED, THE BRAKES WILL NOT APPLY WHEN THE BRAKE PEDAL IS DEPRESSED INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL INSPECT AND REPAIR VEHICLES. OWNER NOTIFICATION WILL BE COMPLETED BY OCTOBER 3, 2003. OWNERS WHO TAKE THEIR VEHICLE TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Defect

CERTAIN SCHOOL BUSES AND HEAVY DUTY TRUCKS BUILT WITH HYDRAULIC BRAKES AND AN AIR POWERED PARKING BRAKE (BRAKE CODE 04GAS) FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." THE HYDRAULIC BRAKE MONITOR MODULE WAS NOT INSTALLED ON CERTAIN VEHICLES.

Consequence

WITHOUT THE BRAKE MONITOR MODULE, THE BRAKE WARNING LIGHT WILL NOT COME ON DURING THE INITIAL KEY-ON CYCLE AND WILL NOT COME ON TO WARN THE OPERATOR IF THERE IS A LOSS OF HYDRAULIC PRESSURE IN THE BRAKE SYSTEM, A LOSS OF POWER STEERING FLOW, OR IF THE EMERGENCY BRAKE BOOSTER MOTOR IS NOT FUNCTIONING.

Remedy

DEALERS WILL INSTALL THE HYDRAULIC BRAKE MONITOR MODULE. OWNER NOTIFICATION IS BEGAN DURING FEBRUARY 2003. 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 INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN MEDIUM AND HEAVY DUTY TRUCKS BUILT WITH DRIVELINE PARKING BRAKE CODES 04GAR, THE PARKING BRAKE ASSEMBLY MAY NOT HOLD THE VEHICLE IN POSITION WHEN SET. FACTORS CONTRIBUTING TO THIS POSSIBILITY ARE AS FOLLOWS: (1) CRACKED OR BROKEN CAMS; (2) LOOSE OR BROKEN ANCHOR BOLTS; (3) INITIAL SHOE DIAMETER NOT SET PROPERLY DURING ASSEMBLY, WHICH CAN LEAD TO PROGRESSIVE COMPONENT DAMAGE; (4) BENT ADJUSTER LEVERS THAT CANNOT FUNCTION; OR (5) AUTOMATIC ADJUSTER CABLES THAT ARE DISCONNECTED.

Consequence

IF THE PARKING BRAKE DOES NOT FUNCTION PROPERLY, THE VEHICLE COULD ROLL, WITHOUT WARNING, AFTER THE PARKING BRAKE LEVER HAS BEEN SET, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE CAM, LEVER, AND BOLT. OWNER NOTIFICATION BEGAN DECEMBER 30, 2002. 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 INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN SCHOOL BUSES AND HEAVY DUTY TRUCKS BUILT WITH INTERNATIONAL VT365 ENGINES AND MANUFACTURED AT INTERNATIONAL DIESEL OF ALABAMA. THE INJECTOR DRIVER MODULES (IDM) BUILT FOR THE VT365 ENGINES COULD HAVE MISSING VIBRATION DAMPING/RETENTION SHELLS AND A MISSING HOT-MELT PROCESS ON THE DC/DC BOARDS.

Consequence

THE MISSING SHELLS COULD ALLOW THE LARGER ELECTRONIC COMPONENTS TO BECOME LOOSE AND POSSIBLE BREAK OFF INSIDE THE MODULE DURING ENGINE OPERATION. DEPENDING ON WHAT ELECTRICAL COMPONENT COMES OFF, THE EFFECT ON ENGINE OPERATION COULD RESULT IN ROUGH RUNNING, LOSS OF POWER, NO START, OR IN THE MOST SEVERE CASE, IMMEDIATE ENGINE SHUT DOWN WITHOUT WARNING, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE IDM MODULES. OWNER NOTIFICATION BEGAN OCTOBER 28, 2002. 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 INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN TRUCKS, THE COTTER PIN THAT GOES THROUGH THE DRAG LINK BALL STUD AT THE CONNECTION TO THE PITMAN ARM IS MISSING. THIS PIN PREVENTS THE CASTLE NUT FROM LOOSENING.

Consequence

IF THE NUT LOOSENS AND COMES COMPLETELY OFF THE DRAG LINK BALL STUD, THE DRAG LINK COULD DETACH RESULTING IN A LOSS OF STEERING CONTROL.

Remedy

DEALERS WILL INSPECT THE VEHICLE AND INSTALL A COTTER PIN IF IT IS MISSING. OWNER NOTIFICATION BEGAN APRIL 15, 2002. 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 INTERNATIONAL AT 1-800-448-7825.