2003 International 9900i 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: 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).

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NHTSA Campaign Number: 04V100000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 4503
Manufactured Begin Date: April 1st, 1994
Manufactured End Date: June 16th, 2002
Date of Owner Notification: July 16th, 2004

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

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO. 04503.CUSTOMERS CAN 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: 03V263000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 3512
Manufactured Begin Date: July 18th, 2002
Manufactured End Date: June 18th, 2003
Date of Owner Notification: November 12th, 2003

Defect Summary:
ON CERTAIN HEAVY DUTY TRUCKS, THE DRAG LINK WILL INTERFERE WITH THE FRONT, DRIVER'S SIDE, BRAKE CHAMBER AND SLACK ADJUSTER. THIS INTERFERENCE COULD CAUSE DAMAGE TO THE SLACK ADJUSTER AND RENDER IT INOPERABLE.

Consequence Summary:
AN INOPERABLE SLACK ADJUSTER WILL CAUSE THE FRONT BRAKES TO WEAR UNEVENLY AND MAY EVENTUALLY CAUSE A VEHICLE CRASH.

Corrective Summary:
DEALERS WILL REPLACE THE PITMAN ARMS, DRAG LINKS, AND STEERING ARMS. OWNER NOTIFICATION BEGAN NOVEMBER 12, 2003. OWNERS SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Recall Notes:
INTERNATIONAL RECALL NO. 03512.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: 03V072000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 3506
Manufactured Begin Date: June 8th, 2001
Manufactured End Date: November 4th, 2002
Date of Owner Notification: March 13th, 2003

Defect Summary:
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 Summary:
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.

Corrective Summary:
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.

Recall Notes:
INTERNATIONAL RECALL NO. 03506.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: 02V309000
Manufacturer: Navistar, Inc.
Manufacturer Campaign Number: 2515
Manufactured Begin Date: July 22nd, 2002
Manufactured End Date: August 16th, 2002
Date of Owner Notification: December 17th, 2002

Defect Summary:
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 Summary:
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.

Corrective Summary:
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.

Recall Notes:
ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).