23501 Insufficient Roof Panel Joint Strength – 2022-2024 IC Bus CE, 2022-2023 IC CE SBus, IC RE, & 2023 EV School Buses

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-065 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : FEB 09, 2023 NHTSA Recall No. : 23V-065 Manufacturer Recall No. : 23501 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 12,507 Estimated percentage with defect : 90 % Vehicle Information : Vehicle 1 : 2022-2024 IC Bus CE SB Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by all models built within the suspect build dates. • The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification. • The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 11,951 CE school buses in the suspect population. Production Dates : SEP 01, 2021 – JAN 12, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-065 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2022-2023 IC Bus CE SBus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by all models built within the suspect build dates. • The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification. • The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 5 CE SBus school buses in the suspect population. Production Dates : NOV 11, 2021 – JAN 10, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2023-2023 IC Bus EV SB Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : • The suspect population is identified by all models built within the suspect build dates. • The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification. • The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 147 EV school buses in the suspect population. Production Dates : SEP 28, 2021 – JAN 09, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-065 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2022-2023 IC RE SB Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by all models built within the suspect build dates. • The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification. • The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 404 RE school buses in the suspect population. Production Dates : SEP 01, 2021 – DEC 16, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : One or more joints that connect the roof top sheets may not meet the requirement of Federal Motor Vehicle Safety Standard No. 221, S5.1. General Performance Requirements for S.6.1.1, S.6.1.2, and S6.2, S6.2 (a), (b), and (c). FMVSS 1 : 221 – School bus body joint strength FMVSS 2 : NR Description of the Safety Risk : In the event of an accident involving the roof of the bus, roof top sheets that do not conform to all the requirements of FMVSS 221 may separate and not protect the occupants sufficiently, increasing the risk of possible injury or death. Description of the Cause : A machine that is not forming the roof bow supports correctly is currently under investigation for root cause. Identification of Any Warning that can Occur : Water leaks into the passenger compartment of the bus may occur. Involved Components : Component Name 1 : Roof Bow Component Description : Roof Bow created in manufacturing process. Component Part Number : NPN Part 573 Safety Recall Report 23V-065 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : • 01/19/2023 – Navistar Manufacturing initiated an investigation of a leaking roof at water test and noticed insufficient overlap of the roof sheeting. • 01/19/2023 and 01/20/2023 – Navistar Manufacturing audits the processes from bow former through topping sheet installation. • 01/24/2023 – Navistar Manufacturing quarantines buses at the assembly plant and contains the issue in manufacturing. • 1/25/2023 When testing compliance to FMVSS 221, Navistar pull tests of three suspect roof joints did not meet the 6,241 pound pull test requirement. Joints separated at 5,645 and 5,026 pounds. • 01/31/2023 – Navistar Manufacturing meets with Compliance to review pull test results and initiate investigation to determine the impact to IC buses. • 02/02/2023 – Navistar determines the suspect population and declares a Non-compliance recall. Description of Remedy : Description of Remedy Program : • The remedy will involve measuring the rivet location for each joint and if they are not within specification, 24 screws will be added to the rear row of rivets to all joints that are out of specification. • Navistar’s plan for reimbursement of pre-notification remedies, on file with NHTSA and dated 05/06/2022, applies and reimbursement instructions will be included in the customer notification. How Remedy Component Differs from Recalled Component : Buses built during this time frame; the bow bender was not forming the roof bows correctly. Buses built prior to this time; the bow bender was producing bows that were formed correctly. Identify How/When Recall Condition was Corrected in Production : 01/23/2023 – Navistar Manufacturing hand oil mists the raw material prior to installation into the roof bow forming machine and rotates the roof bow 180-degrees during installation to the bus chassis which positions the roof bow back into the topping sheet instead of away from the topping sheet. Part 573 Safety Recall Report 23V-065 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 04/03/2023. Planned Dealer Notification Date : APR 03, 2023 – APR 03, 2023 Planned Owner Notification Date : APR 03, 2023 – APR 03, 2023 * NR – Not Reported

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