2003 International 9400i problems

Defect

Navistar, Inc. (Navistar) is recalling certain 2000-2003 International 8100, 2001-2003 International 9100i, 2001-2007 International 9400i, 2001-2010 International 9200i, 2002-2007, 2009 International 8500, 2003-2007, 2013 International 9900i, 2003-2018 International 8600, 2004, 2007 International 9900iX, 2008-2018 International ProStar, 2010-2011, 2013, 2016 International LoneStar, 2011-2012, 2016 International 4400, 2017-2024 International LT, 2018-2024 International RH, 2019-2021 International LS, 2019-2024 International MV vehicles. The back-up lights offer low visibility when the vehicle is in reverse and bobtail mode. Also, the vehicles have not been equipped with additional unobstructed back-up lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence

Low visibility or obstructed back up lights may not alert other drivers that the vehicle is backing up, increasing the risk of a crash.

Remedy

Dealers will replace the existing rear stop/turn signal lights, free of charge. Owner notification letters were mailed May 06, 2024. Owners may contact Navistar's customer service at 1-800-448-7825. Navistar's number for this recall is 23514.

Defect

NAVISTAR IS RECALLING CERTAIN MODEL YEAR 2003 THROUGH 2008 HEAVY TRUCKS MANUFACTURED BETWEEN APRIL 1, 2003 AND DECEMBER 21, 2007, EQUIPPED WITH CATERPILLAR C15 ENGINES. THE VARIABLE VALVE ACTUATION (VVA) OIL LINE MAY WEAR AGAINST THE P-CLIPS RETAINING THE OIL LINE, CAUSING AN OIL LEAK.

Consequence

AN OIL LEAK COULD RESULT IN A FIRE.

Remedy

NAVISTAR IS WORKING WITH CATERPILLAR TO REPAIR THE ENGINES FREE OF CHARGE. PLEASE SEE 09E-020. THE SAFETY RECALL BEGAN ON OCTOBER 23, 2009. OWNERS MAY CONTACT CATERPILLAR AT 1-800-447-4986 OR NAVISTAR AT 1-260-461-1890.

Defect

ON CERTAIN 4X2 AND 6X4 HEAVY DUTY TRUCKS, THE POSITIVE BATTERY CABLE BETWEEN THE BATTERIES AND THE STARTER MAY RUB AGAINST AN ELECTRICAL GROUND CABLE BETWEEN THE STARTER AND FRAME RAIL.

Consequence

THIS CHAFING COULD CAUSE AN ELECTRICAL SHORT AND/OR FIRE.

Remedy

DEALERS WILL INSPECT THE VEHICLES TO DETERMINE IF ANY CHAFING HAS OCCURRED BETWEEN POSITIVE AND NEGATIVE CABLES. IF THERE IS NO EVIDENCE OF CHAFING, THEN A SADDLE CLAMP WILL BE INSTALLED TO ENSURE CABLES WILL NOT RUB. IF THERE IS EVIDENCE OF CHAFING, THE DAMAGED CABLES WILL BE REPLACED AND THE SWIVEL SADDLE CLAMP INSTALLED. THE RECALL BEGAN ON AUGUST 22, 2005. OWNERS MAY CONTACT INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN HEAVY DUTY TRUCKS, THE ENGINE ELECTRICAL HARNESS CAN CHAFE AGAINST SHARP EDGES ON THE ENGINE.

Consequence

SUDDEN ACCELERATION, ACTIVATION OF THE ENGINE COMPRESSION BRAKE, ENGINE SPEED DROPPING TO IDLE, ALTERNATOR OVERLOAD WITH POSSIBLE FIRE, AND A LOSS OF ENGINE ECM POWER RESULTING IN ENGINE SHUTDOWN COULD OCCUR WITHOUT WARNING.

Remedy

DEALERS WILL INSPECT THE HARNESS TO DETERMINE IF IT IS DAMAGED. IF DAMAGED, THE ENGINE HARNESS WILL BE REPAIRED. ALL HARNESSES WILL BE RE-ROUTED AND STAND-OFF BRACKETS WILL BE ADDED. THE RECALL BEGAN ON SEPTEMBER 8, 2004. OWNERS CAN CONTACT INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN CONVENTIONAL TRUCKS EQUIPPED WITH PRO-SLEEPER BERTHS, WATER INTRUSION CAN BE FOUND IN THE BUNK CONTROL PANEL AREA AND POOL IN THE TOPS OF THE DOME LIGHT, TV/VCR, AND OR REFRIGERATOR POWER SWITCHES.

Consequence

THE CIRCUIT BOARDS IN THE SWITCHES COULD HEAT UP , POSSIBLY PRODUCE A FLAME OR FIRE, AND CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy

DEALERS WILL INSTALL A WATER SHIELD OVER THE BACK OF THE ENTIRE BUNK CONTROL PANEL. OWNER NOTIFICATION BEGAN ON JULY 16, 2004. OWNERS SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Defect

ON CERTAIN HEAVY DUTY TRUCKS BUILT WITH INTERNATIONAL CODE 16SCH (LOWER BUNK WEBBING RESTRAINT). FOUR BOLTS HOLD THE BUNK WEBBING RESTRAINT LATCH BRACKETS TO THE BUNK BASE. THESE BOLTS WERE SUPPOSED TO BE GRADE 8 BOLTS BUT GRADE 5 BOLTS WERE INSTALLED.

Consequence

IN THE EVENT OF A CRASH, THE RESTRAINT MAY NOT CONTAIN THE OCCUPANT AS REQUIRED BY FEDERAL MOTOR CARRIER SAFETY REGULATION 393.76 "SLEEPER BERTHS," AND MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy

DEALERS WILL INSPECT AND REPLACE ALL GRADE 5 BOLTS WITH GRADE 8 BOLTS. OWNER NOTIFICATION BEGAN ON MARCH 17, 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 HEAVY DUTY TRUCKS BUILT WITH A DETROIT ENGINE AND A LEECE NEVILLE ALTERNATOR. THE ELECTRICAL TERMINAL AT THE ALTERNATOR END OF THE CABLE THAT RUNS FROM THE STARTER TO THE BATTERY STUD ON THE ALTERNATOR MAY BREAK OFF, DUE TO VIBRATION IN THE CABLE.

Consequence

IF THE TERMINAL BREAKS OFF, THE CAB WILL LOSE ALL POWER, RESULTING IN COMPLETE ELECTRICAL FAILURE AND ENGINE SHUTDOWN, WHICH MAY RESULT IN A CRASH AND POTENTIALLY CAUSE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy

DEALERS WILL REROUTE AND REWIRE THE WIRING HARNESS TO THE ALTERNATOR. OWNER NOTIFICATION BEGAN ON MARCH 13, 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 HEAVY DUTY TRUCKS, THE BOLTS AND LOCKING NUTS USED TO HOLD THE BRAKE SPIDERS OR BRAKE ANCHOR PLATES TIGHT TO THE AXLES WERE UNDER-TORQUED ON THE RIGHT SIDE OF THE VEHICLES. IF THE CLAMP LOAD ON THE BOLTS IS NOT SUFFICIENT, THE ANCHOR PLATE MAY MOVE WHEN THE BRAKE IS APPLIED IN EITHER THE FORWARD OR REVERSE DIRECTION.

Consequence

THIS MOVEMENT COULD CAUSE INDIVIDUAL BRAKE COMPONENTS TO FAIL OR EVENTUALLY FATIGUE ALL THE ANCHOR PLATE MOUNTING BOLTS. IF ALL THE BOLTS BREAK DUE TO FAILURE, A COMPLETE LOSS OF BRAKING AT A WHEEL END COULD OCCUR.

Remedy

DEALERS WILL INSPECT AND TIGHTEN ALL SUSPECT BOLTS. NEW WHEEL SEALS AND NEW BOLTS WILL BE INSTALLED WHERE APPLICABLE. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING DECEMBER 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.