23505 Driveshaft Separation – 2023 International HV & 2023-2024 International MV

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-153 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : MAR 08, 2023 NHTSA Recall No. : 23V-153 Manufacturer Recall No. : 23505 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 660 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2023-2023 International HV Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with feature code 14VAD, 14VAG, or 14VAH (Suspension, rear, single with vary-rate springs). • The Inclusive dates of manufacture were determined by when the San Antonio manufacturing plant began production of the HV® and MV® series trucks through the date the issue was contained in production. • The vehicles in the suspect population were assembled at the San Antonio assembly plant and all other similar vehicles not in the suspect population were assembled with a different feature code or at Navistar’s other manufacturing plants. There are 6 HV series trucks in the suspect population. Production Dates : APR 29, 2022 – DEC 07, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-153 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2023-2024 International MV Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with feature code 14VAD, 14VAG, or 14VAH (Suspension, rear, single with vary-rate springs). • The Inclusive dates of manufacture were determined by when the San Antonio manufacturing plant began production of the HV® and MV® series trucks through the date the issue was contained in production. • The vehicles in the suspect population were assembled at the San Antonio assembly plant and all other similar vehicles not in the suspect population were assembled with a different feature code or at Navistar’s other manufacturing plants. There are 654 MV series trucks in the suspect population. Production Dates : FEB 24, 2022 – JAN 18, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The rear axle spring wedge shim may have been installed incorrectly oriented (180-degrees). An incorrectly oriented axle spring wedge shim can result in driveline angles out of specification. Driveline angles out of specification can cause premature wear and eventual failure of a U-joint which could result in drive shaft separation from the vehicle. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : U-joint failure resulting in drive shaft separation from the vehicle can increase the risk of a vehicle crash resulting in property damage, personal injury, or death. Description of the Cause : The spring wedge shim has two part numbers (P/N) on each end and the work instructions did not specify orientation by P/N for all variations. Identification of Any Warning that can Occur : Increased driveline vibration and/or noise over time. Involved Components : Component Name 1 : Wedge, shim Component Description : Wedge, Spring 6-degree rear/2-degree rear Component Part Number : 3518107C1/495364C1 Part 573 Safety Recall Report 23V-153 Page 3 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 : • 02/01/2023 – Navistar Manufacturing Product Engineering discovers workstation responsible for rear axle and suspension assembly was installing the spring wedge shim in the same orientation regardless of the suspension configuration requirements. • 02/06/2023 – Navistar Manufacturing quarantines all vehicles at the plant and inspects wedge shim orientation of suspect vehicles. • 02/08/2023 – Navistar Manufacturing updates the work instructions to illustrate correct orientation of wedge shims according to configuration requirements. • 02/13/2023 – Navistar Manufacturing and Engineering meet to determine failure mode of suspect population. • 02/22/2023 – Navistar Manufacturing and Engineering meet with Compliance to discuss analysis of failure mode, root cause in manufacturing, and the effect on driveline angles. The team then initiates risk assessment of the incorrect driveline angles. • 02/28/2023 – Navistar Manufacturing, Engineering and Compliance conclude risk analysis and determines the impact to the suspect population. • 03/01/2023 – Navistar finalizes the suspect population. • 03/02/2023 – Navistar declares a Safety Recall. Description of Remedy : Description of Remedy Program : • The remedy will involve correctly orienting the rear axle wedge shim on both the left and right side of the rear axle spring suspension. • 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 : The remedy assembly correctly orients the rear axle wedge shims where the recalled assembly incorrectly oriented the rear axle shim wedges. Identify How/When Recall Condition was Corrected in Production : 02/27/2023 – Navistar manufacturing corrects the issue by updating the work instructions to specify correct orientation of the spring wedge shims according to configuration requirements. Part 573 Safety Recall Report 23V-153 Page 4 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 05/05/2023. Planned Dealer Notification Date : MAY 05, 2023 – MAY 05, 2023 Planned Owner Notification Date : MAY 05, 2023 – MAY 05, 2023 * NR – Not Reported

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