2012 International LONESTAR: complaints, problems and recalls

Reported: 2011-04-19 (April 19, 2011)

NAVISTAR IS RECALL CERTAIN MODEL YEAR 2011 AND 2012 INTERNATIONAL DURASTAR, PAYSTAR, WORKSTAR, TRANSTAR, LONESTAR AND PROSTAR COMMERCIAL TRUCKS MANUFACTURED FROM NOVEMBER 5, 2010, THROUGH MARCH 10, 2011, FOR FAILING TO COMPLY WITH FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS (ABS)." THE TRAILER ABS FAULT INDICATOR LAMP IN THE INSTRUMENT CLUSTER WILL NOT ILLUMINATE DUE TO A PROGRAMMING OR HARDWARE ISSUE WITH THE BRAKE SYSTEM ELECTRONIC CONTROL UNIT.

Consequence: AN INOPERABLE TRAILER ABS FAULT INDICATOR MAY PREVENT THE DRIVER FROM BEING AWARE OF A TRAILER ABS FAULT CONDITION THEREBY POSSIBLY INCREASING THE RISK OF A CRASH POTENTIALLY RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy: NAVISTAR WILL NOTIFY OWNERS. DEALERS WILL REPROGRAM OR REPLACE THE BRAKE SYSTEM ELECTRONIC CONTROL UNIT FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 12, 2011. OWNERS MAY CONTACT NAVISTAR AT 1-800-448-7825.

Reported: 2012-02-13 (February 13, 2012)

NAVISTAR IS RECALLING CERTAIN MODEL YEAR 2012-2013 IC BUS CE-C, HC, AND INTERNATIONAL 9400 AND CERTAIN MODEL YEAR 2011 THROUGH 2013 INTERNATIONAL DURASTAR, PAYSTAR, WORKSTAR, TRANSTAR, LONESTAR, PROSTAR, 9200, AND 9800, AND CERTAIN MODEL YEAR 2013 INTERNATIONAL 9900, VEHICLES, MANUFACTURED FROM DECEMBER 2, 2010, THROUGH JANUARY 26, 2012, AND EQUIPPED WITH BENDIX ATR-6 TRACTION RELAY VALVES. IN EXTREMELY COLD CONDITIONS, THESE BENDIX RELAY VALVES MAY POTENTIALLY DEVELOP INTERNAL LEAKAGE. INTERNAL LEAKAGE CAN LEAD TO AIR PRESSURE BEING DELIVERED TO AFFECTED PRIMARY OR SECONDARY BRAKES CAUSING CONTINUOUS BRAKE APPLICATION.

Consequence: UNEXPECTED CONTINUOUS BRAKE APPLICATION CAN CAUSE THE BRAKES TO OVERHEAT AND LEAD TO A FIRE. UNEXPECTED CONTINUOUS BRAKE APPLICATION CAN CAUSE THE DRIVER TO LOSE CONTROL OF THE VEHICLE, INCREASING THE RISK OF A CRASH. ALSO, THE BRAKES MAY BE APPLIED WITHOUT ILLUMINATING THE BRAKE LIGHTS, FAILING TO GIVE PROPER WARNING TO OTHER DRIVERS.

Remedy: NAVISTAR WILL NOTIFY OWNERS, AND DEALERS WILL PROVIDE A TEMPORARY REPAIR UNTIL BENDIX DEVELOPS A PERMANENT REMEDY. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 10, 2012. OWNERS MAY CONTACT NAVISTAR AT 1-800-448-7825.

Reported: 2012-03-22 (March 22, 2012)

NAVISTAR IS RECALLING CERTAIN MODEL YEAR 2012 INTERNATIONAL LONESTAR AND PROSTAR TRUCKS, MANUFACTURED FROM MARCH 24, 2011, THROUGH NOVEMBER 22, 2011, EQUIPPED WITH a FEATURE CODE 08VTS, 08JAU, OR 08JAW BATTERY BOX. THE MOUNTING BRACKETS USED TO INSTALL THE BATTERY BOX LOWER STEP WERE ASSEMBLED WITH TWO WELDS INSTEAD OF THREE WELDS AND MAY CAUSE THE STEP MOUNT TO BREAK OFF FROM THE BRACKET.

Consequence: A FAILURE OF THE STEP MOUNTING BRACKET MAY CAUSE THE STEP TO UNEXPECTEDLY BREAK OFF WHICH CAN RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy: NAVISTAR WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE BOTH STEP MOUNTING BRACKETS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 6, 2012. OWNERS MAY CONTACT NAVISTAR AT 1-800-448-7825.

Reported: 2012-05-02 (May 2, 2012)

NAVISTAR IS RECALLING CERTAIN MODEL YEAR 2010 THROUGH 2013 PAYSTAR, WORKSTAR, TRANSTAR, AND PROSTAR, AND MODEL YEAR 2012 AND 2013 LONESTAR COMMERCIAL TRUCKS MANUFACTURED FROM JUNE 1, 2009, THROUGH APRIL 4, 2012, EQUIPPED WITH A MAXXFORCE 11 OR 13 ENGINE (FEATURE CODE 12UXJ OR 12UXH) AND WITH BOSCH ALTERNATOR FEATURE CODES 08GGN, 08GGR, 08GHG, OR 08GHH. THE ALTERNATOR CABLE MAY RUB ON THE HIGH PRESSURE POWER STEERING HOSE, POSSIBLY CHAFING ITS INSULATION AND CAUSING AN ELECTRICAL SHORT.

Consequence: AN ELECTRICAL SHORT MAY CAUSE A VEHICLE FIRE POSSIBLY RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

Remedy: NAVISTAR WILL INSTALL A STANDOFF BRACKET AND IMPROVE HARNESS ROUTING TO BETTER ROUTE THE ALTERNATOR WIRES AWAY FROM THE POWER STEERING HOSE. THE SAFETY RECALL BEGAN ON JULY 16, 2012. OWNERS MAY CONTACT NAVISTAR AT 1-800-448-7825.

Reported: 2013-04-17 (April 17, 2013)

Navistar is recalling certain model year 2011-2012 International Lonestar, model year 2012-2013 International Terrastar and model year 2011-2013 International DuraStar, ProStar, TranStar, and WorkStar commercial trucks manufactured from June 1, 2010, through March 7, 2012 and equipped with day cab codes 16CAB, 16030, or 16196 and feature codes 16WCE, 16WCR, 16XWD, 16XWE, 16XWV, 16XXB, 16XXD, 16XXE, 16XXG, or 16XYN sun shades. The sun shade may not be properly secured to the cab roof panel which may result in partial or full separation of the sun shade from the roof panel.

Consequence: If the sun shade separates from the cab roof during vehicle operation, the sudden release of the sun shade could distract the driver increasing the risk of a crash.

Remedy: Navistar will notify owners, and dealers will inspect and strengthen the sun shade mounting, free of charge. The safety recall began on September 10, 2013. Owners may contact Navistar at 1-800-448-7825. Navistar's campaign number is 13505.

Reported: 2013-09-18 (September 18, 2013)

Navistar, Inc. is recalling certain model year 2008-2013 International LoneStar, ProStar, and TranStar trucks manufactured February 20, 2008, through July 29, 2013 and equipped with an electronic fifth wheel jaw release system (feature code 0595BAW or 0595BAY). Due to an assembly error, the air lines at the isolation/vent valve may not be oriented correctly.

Consequence: Because of the improper orientation, in the event of an air leakage at the isolation/vent valve, the 5th wheel jaw may release, unexpectedly releasing the trailer from the tractor, increasing the risk of a vehicle crash.

Remedy: Navistar will notify owners, and dealers will inspect the air line routing. If necessary, the air line routing will be corrected free of charge. The recall began on October 10, 2013. Owners may contact Navistar at 1-331-332-1590. Navistar's recall number is 13514.

Reported: 2014-02-20 (February 20, 2014)

Navistar Inc., is recalling certain model year 2012-2013 International Lonestar, Paystar, Prostar, Workstar and 9900 trucks, equipped with feature code 0504501, 0504504, or 04EWM Reduced Stopping Distance (RSD) brake linings and with or without feature code 04WCS Greased For Life front air S-cam brakes. In the affected vehicles, the brake S-cam brackets may fracture.

Consequence: S-cam bracket fractures may result in an inoperative brake on the affected wheel. This will cause the vehicle to pull to one side unexpectedly during braking and/or increase the stopping distance. Either result may increase the risk of a crash.

Remedy: Navistar will notify owners, and dealers will replace the S-cam brake assemblies with a brake assembly with cast spiders and S-cam tube bracket assemblies with reinforced gussets, free of charge. The recall began on March 27, 2014. Owners may contact Navistar at 1-331-332-1590. Navistar's number for this recall 14501. Note: This recall is an expansion of recall 13V231.

Reported: 2014-10-31 (October 31, 2014)

Navistar, Inc. (Navistar) is recalling certain model year 2010-2015 International Lonestar vehicles manufactured October 12, 2009, to June 16, 2014, and 2009-2015 International ProStar vehicles manufactured December 16, 2008, to June 20, 2014. In the affected vehicles the electrical harness that supplies power to the HVAC system may not be of sufficient size for the electrical load of the circuit. This can result in an increase in resistance and heating at the connectors.

Consequence: An increase in resistance and heating at the connectors could cause a vehicle fire.

Remedy: Navistar will notify owners, and dealers will replace the 60 amp relay and battery harness with a 150 amp relay and battery harness, free of charge. Navistar issued an interim notification to owners on December 29, 2014. The recall began on March 2, 2015. Owners may contact Navistar customer service at 1-331-332-1590. Navistar's number for this recall is 14516.

Reported: 2015-09-29 (September 29, 2015)

Navistar, Inc. (Navistar) is recalling certain model year 2011-2014 International ProStar trucks manufactured May 18, 2010, to April 5, 2013, 2012-2014 International LoneStar trucks manufactured September 7, 2011, to March 25, 2013, and 2011-2013 International TranStar trucks manufactured October 18, 2010, to February 20, 2013. The affected trucks are equipped with Fontaine Ultra LT Fifth Wheel connectors, which, due to cumulative damage to the fifth wheel and its locking mechanism, have a locking mechanism that may fail to operate or to properly engage.

Consequence: If the fifth wheel and locking mechanism are sufficiently damaged, the locking mechanism may fail to operate as intended and the trailer may unexpectedly detach from the tractor, increasing the risk of a crash.

Remedy: Navistar will notify owners, and Fontaine dealers will replace the fifth wheel with an Ultra NT model fifth wheel, free of charge. The recall began on November 18, 2015. Owners may contact Navistar customer service at 1-800-448-7825, or Fontaine customer service at 1-844-597-7393.