2004 International 9200i Recalls

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NHTSA Campaign Number: 09V386000
Manufacturer: Navistar, Inc.
Manufactured Begin Date: April 1st, 2003
Manufactured End Date: December 21st, 2007
Date of Owner Notification: October 13th, 2009

Defect Summary:
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 Summary:
AN OIL LEAK COULD RESULT IN A FIRE.

Corrective Summary:
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.

Recall Notes:
OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .

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NHTSA Campaign Number: 05V296000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 5514
Manufactured Begin Date: April 1st, 2002
Manufactured End Date: June 15th, 2005
Date of Owner Notification: July 22nd, 2005

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

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO. 05514.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

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NHTSA Campaign Number: 04V416000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 4516
Manufactured Begin Date: July 26th, 2004
Manufactured End Date: July 28th, 2004
Date of Owner Notification: September 22nd, 2004

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

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO.04516.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

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NHTSA Campaign Number: 04V415000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 4515
Manufactured Begin Date: July 26th, 2004
Manufactured End Date: July 29th, 2004
Date of Owner Notification: September 15th, 2004

Defect Summary:
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 Summary:
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.

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO. 04515.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

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NHTSA Campaign Number: 04V307000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 4511
Manufactured Begin Date: June 2nd, 2002
Manufactured End Date: January 13th, 2004
Date of Owner Notification: September 8th, 2004

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

Consequence Summary:
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.

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO. 04511. CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).