International 9400I recalls by model year

Reported: 2004-02-27 (February 27, 2004) · Model years: 1995, 2002, 2003

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.

Reported: 2023-05-18 (May 18, 2023) · Model years: 2001, 2002, 2003, 2004, 2005, 2006, 2007

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.

Reported: 2003-03-06 (March 6, 2003) · Model years: 2002, 2003

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.

Reported: 2004-06-30 (June 30, 2004) · Model years: 2002, 2003, 2004

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.

Reported: 2002-11-15 (November 15, 2002) · Model years: 2003

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.

Reported: 2003-03-06 (March 6, 2003) · Model years: 2003

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.

Reported: 2005-06-24 (June 24, 2005) · Model years: 2003, 2004, 2005, 2006

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.

Reported: 2009-10-05 (October 5, 2009) · Model years: 2003, 2004, 2005, 2006, 2007, 2008

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.

Reported: 2004-08-25 (August 25, 2004) · Model years: 2004

ON CERTAIN TRUCKS, ONLY EIGHT (8) BOLTS WERE INSTALLED IN THE BRAKE GROUP CONNECTION TO THE REAR AXLES. THE BRAKE GROUP, AN ASSEMBLY THAT INCLUDES THE BRAKE SHOES, AIR CHAMBERS, SLACK ADJUSTERS, AND SPIDER, IR NORMALLY ATTACHED TO THE AXLE HOUSING WITH NINE (9) BOLTS.

Consequence: THE STRUCTURAL INTEGRITY OF THE BRAKE GROUP IS QUESTIONABLE. THIS MAY RESULT IN THE LOSS OF BRAKING ABILITY ON THE REAR AXLES WITHOUT WARNING, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT AND INSTALL THE ADDITIONAL BOLT IF NECESSARY. THIS RECALL BEGAN DURING SEPTEMBER 2004. OWNERS SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2004-08-25 (August 25, 2004) · Model years: 2004

ON CERTAIN TRUCKS, THE FRONT, NON-DRIVE AXLE, COTTER KEYS AND SPINDLE NUT RETAINERS WERE NOT INSTALLED. THE COTTER KEY AND SPINDLE NUT RETAINER PREVENT THE SPINDLE NUT FROM LOOSENING AND THUS AID IN WHEEL RETENTION.

Consequence: A WHEEL-OFF CONDITION MAY OCCUR WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT TO DETERMINE IF VEHICLE REQUIRES A RETAINER AND COTTER KEY INSTALLED. THIS RECALL BEGAN ON SEPTEMBER 22, 2004. OWNERS SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2006-03-17 (March 17, 2006) · Model years: 2006

ON CERTAIN TRUCKS, THE HOSE CONNECTING THE ENGINE BLOCK TO THE FRAME IS ROUTED NEAR THE ENGINE'S TURBOCHARGER. HEAT FROM THE TURBOCHARGER MAY CAUSE THE HOSE TO MELT.

Consequence: IF MELTING OF THE HOSE OCCURS, ENGINE OIL COULD SPRAY UPWARD ONTO THE SURFACE OF THE TURBOCHARGER HOUSING POSSIBLY CAUSING SMOKE OR A FIRE. THIS MAY LEAD TO PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Remedy: DEALERS WILL REPLACE THE HOSE FREE OF CHARGE WITH A HIGHER THERMAL RESISTANCE AND A KEVLAR REFLECTIVE HEAT WRAP WILL BE INSTALLED OVER THE NEW HOSE. THE RECALL BEGAN ON MAY 25, 2006. OWNERS MAY CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2007-04-24 (April 24, 2007) · Model years: 2007, 2008

ON CERTAIN TRUCKS, ONE OR BOTH REAR AXLE HOUSINGS MAY CONTAIN THINNER MATERIAL THAN WHAT IS NECESSARY FOR NORMAL VEHICLE OPERATION. OVER TIME, THIS THINNER MATERIAL MAY RESULT IN A FATIGUE FAILURE OF THE REAR AXLE HOUSING, POSSIBLY IN THE LOCATION OF THE BRAKE FLANGE.

Consequence: A CRACK IN THE BRAKE FLANGE LOCATION OF THE REAR AXLE HOUSING MAY RESULT IN A WHEEL END LOCKUP OR WHEEL SEPARATION POSSIBLY RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy: DEALERS WILL INSPECT THE VEHICLE'S REAR AXLES AND, IF NECESSARY, REPLACE THE AXLE HOUSINGS. THE RECALL BEGAN ON MAY 18, 2007. OWNERS MAY CONTACT INTERNATIONAL AT 1-800-448-7815.

Reported: 2007-04-24 (April 24, 2007) · Model years: 2007, 2008

ON CERTAIN TRUCKS EQUIPPED WITH DAVCO FUEL PRO 382 HEATED FUEL FILTERS, WHEN THE KEY IS IN THE 'ON' POSITION, THE PRE-HEATER, LOCATED IN THE FUEL FILTER BASE, IS ENERGIZED.

Consequence: IF THIS PRE-HEATER IS ENERGIZED WHILE MAINTENANCE IS BEING PERFORMED ON THE FUEL FILTER, DIESEL FUEL COULD IGNITE WITHIN THE FILTER HOUSING. A FIRE WITHIN THE FUEL FILTER HOUSING MAY SPREAD POSSIBLY RESULTING IN PROPERTY DAMAGE OR PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THE FUEL FILTERS AND FUEL HEATERS AND, IF NECESSARY, WILL REPLACE THE FUEL HEATER. THE RECALL BEGAN ON MAY 11, 2007. OWNERS MAY CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2007-06-05 (June 5, 2007) · Model years: 2007

ON CERTAIN TRUCKS, THE DIESEL ENGINE/GENERATOR UNIT CAN BE STARTED REMOTELY BY A PERSON IN THE TRUCK CAB WHILE ITS PROTECTIVE COVER IS REMOVED; AND UNDER CERTAIN CONDITIONS THE ENGINE MAY RE-START AFTER THE EMERGENCY FUEL CUTOFF IS USED TO SHUT DOWN THE UNIT.

Consequence: AN UNEXPECTED STARTING OF THE DIESEL ENGINE/GENERATOR UNIT, WHEN THE PROTECTIVE COVER IS REMOVED AND MAINTENANCE IS BEING PERFORMED, MAY RESULT IN PERSONAL INJURY.

Remedy: DEALERS WILL UPDATE THE AUXILIARY POWER SYSTEM WITH A NEW ELECTRONIC CONTROL UNIT CONTAINING PROGRAMMING TO PREVENT DIESEL ENGINE/GENERATOR OPERATION WHILE ITS PROTECTIVE COVER IS REMOVED. NEW WARNING LABELS WILL BE INSTALLED ON THE DIESEL ENGINE/GENERATOR UNIT AND COVER. ORANGE CONDUIT WILL BE INSTALLED ON ALL HIGH VOLTAGE POWER CABLES. THE RECALL BEGAN ON JUNE 29, 2007. OWNERS MAY CONTACT INTERNATIONAL AT 1-800-448-7825.