2008 International 4200: complaints, problems and recalls

ENGINE START HARNESS HAS A 40 AMP FUSE INSTALLED IN A 30 AMP RATED FUSE HOLDER. HOLDER WILL OVER HEAT (MELT) WITHOUT BLOWING FUSE, CAUSING THE METAL CONTACTS TO CHAR / LOOSEN,CAUSING AN OPEN RUN CIRCUIT, WHICH CAUSES THE ENGINE TO STALL. THIS CAN HAPPEN AT ANY TIME, IDLE, RUNNING IN STOP AND GO TRAFFIC AND AT FREEWAY SPEEDS. WHEN THIS OCCURS YOU LOOSE ALL ENGINE BASED ASSIST, ELECTRICAL, POWER STEERING,LIGHTING. NAVSTAR (INTERNATIONAL) HAS ADDRESSED THIS ISSUE ON SCHOOL BUS CHASSIS, BUT SAYS THE PROBLEM DOESN'T EXIST ON APPROXIMATELY 250 CHASSI…

Owner-reported narrative. Look up ODI 10594727 at NHTSA ↗

Reported: 2007-04-24 (April 24, 2007)

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: 2010-03-16 (March 16, 2010)

NAVISTAR HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2010 AND 2011 IC CE, HC, AND BE COMMERCIAL BUSES AND INTERNATIONAL 1300, 3200, 3300, 4100, 4200, 4300, 4400, AND MXT TRUCKS MANUFACTURED FROM NOVEMBER 19, 2003 THROUGH FEBRUARY 9, 2010. THE PARKING BRAKE MAY RELEASE IF THE BRAKE SYSTEM ELECTRONIC CONTROL UNIT (ECU) SOFTWARE MISINTERPRETS INPUT SIGNALS GENERATED FROM CYCLING THE IGNITION SWITCH MORE THAN ONCE AT A SPECIFIC FREQUENCY.

Consequence: RELEASE OF THE PARKING BRAKE MAY CAUSE SUDDEN, UNEXPECTED SHIFT IN VEHICLE POSITION POSSIBLY RESULTING IN PROPERTY DAMAGE, PERSONAL DAMAGE, OR DEATH.

Remedy: NAVISTAR WILL NOTIFY OWNERS AND WILL REPAIR THE VEHICLES BY REPROGRAMMING THE VEHICLE'S BRAKE SYSTEM ECU FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 14, 2010. OWNERS MAY CONTACT NAVISTAR AT 1-260-461-1890.

Reported: 2010-06-15 (June 15, 2010)

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.