Recall 23507 Grille Surround May Detach From Vehicle – 2020-2024 International HX

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March 16, 2023 NHTSA CAMPAIGN NUMBER: 23V170000

Grille Surround May Detach From Vehicle

A detached grille surround can fall to the roadway and become a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V170

Manufacturer Navistar, Inc.

Components STRUCTURE

Potential Number of Units Affected 5,808

 

Summary

Navistar, Inc. (Navistar) is recalling certain 2020-2024 International HX vehicles. The grille surround may corrode and detach from the truck.

 

Remedy

Dealers will replace the grille surround, free of charge. Owner notification letters were mailed November 21, 2023. Owners may contact Navistar’s customer service at 1-800-448-7825. Navistar’s number for this recall is 23507.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 


23507
May, 2023

SAFETY RECALL

Grille surround on certain 2020 thru 2024 International® HX® Series trucks built 03/13/2019 thru 02/28/2023

 

DEFECT DESCRIPTION

Over time, the grille surround may come loose from the eight mounting brackets that secure it to the hood. This may cause the grille surround to separate from the truck. A grille surround that separates from the truck and falls to the roadway while the vehicle is in operation can increase the risk of a vehicle crash that may result in property damage, personal injury, or death.

 

MODELS INVOLVED

This safety recall involves certain 2020 thru 2024 International® HX® Series trucks built 03/13/2019 thru 02/28/2023.

 

SPECIAL TOOLS

Tool Description Part Number
Rivet Gun Rivet Gun with mandrel for 3/16-inch diameter rivets (manual or pneumatic) N/A
#11 Drill Bit Drill Bit N/A
Black Permanent Marker Black Permanent Marker N/A
Pneumatic Grinder Pneumatic Grinder N/A
Pneumatic Rotary Sanding Wheel Pneumatic Rotary Sanding Wheel N/A

 

PARTS INFORMATION

CAUTION! To prevent damage to property, the rivets specified for this repair must be used and NOT substituted with any other type. These rivets are available from the sources listed in the table below.

Part Number Part Description Quantity
Fastenal P/N: 126282 Grainger P/N: 97525A490 McMaster-Carr P/N: 3ZKT1 Rivet: 3/16-in Dia. Stainless Steel w/0.125-in-0.25-in Grip Range 28
NPN / Source Locally Heavy Double-Sided Tape As Needed

 

SERVICE PROCEDURE

1. Park vehicle on flat surface.

2. Shift transmission to Park or Neutral and set parking brake.

3. Turn vehicle ignition to Key OFF position.

4. Install wheel chocks.

NOTE: ONLY grille surrounds found loose shall receive the interim repair.
There should be no inspection only claims so the recall stays open should the grille surround become loose prior to final Remedy.

NOTE: Refer to Figure 3 for HX615 and HX620 models. Refer to Figure 4 for HX520 models to determine where the mounting brackets are located.

5. Using hand force, pull the grille surround away from the hood to see if one or more brackets have de-bonded from the grille surround.

a. If one or more areas of the grille surround moves, proceed to Step 6.

b. If the grille surround does not move, then no repair is required at this time.
Proceed to Step 28.

 

Instructions for Grille Surround Removal for HX615 and HX620 Series Trucks

6. Unlatch and open hood.

 

7. Remove eight MB Keps nuts (Figure 1, Item 3) from the back of grille surround (Figure 1, Item 4 ). Save Keps nuts for reuse.

8. Remove grille assembly (Figure 1, Item 2) from truck by pushing inward and rotating 90 degrees to remove it through hood opening.

9. Remove two palnuts from stud (Figure 1, Item 1) by rotating them counterclockwise. Save palnuts for reuse.

10. Remove grille surround (Figure 1, Item 4) from hood and place face down on a clean, protected workbench.

 

Instructions for Grille Surround Removal for HX520 Series Trucks

NOTE: The eight MS Tone® bolts must be returned to their original positions when grille assembly is installed. (MS Tone® bolts vary in length.)

11. With hood closed, remove eight MB Tone® bolts (Figure 2, Item 3) from center of grille assembly (Figure 2, Item 4). Save Tone® bolts for reuse.

12. Remove grille assembly (Figure 2, Item 4) and safely set aside.

13. Remove eight MB prevailing torque nuts (Figure 2, Item 2) from back of grille surround (Figure 2, Item 1 ). Save nuts for reuse.

14. Remove grille surround from hood and place face down on a clean, protected workbench.

NOTE: All support brackets must be repaired whether they are still attached, loose on one pad and not fully detached, or fully detached.

15. Determine condition of support bracket mounting.

16. For each support bracket that is loose on one pad but not fully detached, perform the following:

a. Press the loose pad back down to the original location on the back side of the grille surround.

b. Using heavy double-sided tape or a clamp, hold support bracket in place on grille surround for drilling and riveting.

17. For each support bracket that is fully detached from the grille surround, perform the following:

a. Using pneumatic grinder with rotary sanding wheel, clean rust and I or corrosion from both the grille surround and the mounting surface of the support brackets.

b. Apply a 2-inch strip of heavy double-sided tape to each pad of the mounting brackets.

c. Install the detached mounting brackets into their correct location on the hood.

i. For HX615 and HX620 Series trucks, install the M8 Keps nuts to hold the mounting brackets in place for each separated mounting bracket.

ii. For HX520 Series trucks, install eight M8 prevailing torque nuts to hold the mounting brackets in place. Install M8 prevailing torque nut to hold each separated mounting bracket to keep it in place.

d. Once all brackets are installed and secured, install grille surround onto the hood.

e. Apply hand pressure at each location of grille surround. Use the palm of one hand on the grille surround and the fingers of your other hand on the back side of bracket.

f. Once pressure has been applied to each location, remove nuts installed in step 17. c. i or Step 17. c. ii, and remove grille surround.

g. Proceed to Step 18.

 

NOTE: Refer to Figure 3 for HX615 and HX620 drill locations.

 

NOTE: Refer to Figure 4 for HX520 drill locations.

 

18. Drill 28 #11 diameter holes from back side.

a. Refer to Figure 3 for HX615 and HX620 Series trucks.

b. Refer to Figure 4 for HX520 Series trucks.

19. Once all holes have been drilled, turn grille surround over, deburr each hole taking care not to increase the diameter, and install rivets from front side in all 28 locations.

20. Once all rivets have been installed, inspect each rivet for correct installation.

 

Instructions for Grille Surround Installation on HX615 and HX620 Series Trucks

21. With hood in open position, install grille surround and position on hood and install palnuts.

22. Install grille assembly inserting it through hood front opening, rotate grille 90 degrees, and position into place.

23. Install eight M8 Keps nuts.

24. Close and latch hood.

25. Remove wheel chocks.

 

Instructions for Grille Surround Installation on HX520 Series Trucks

26. With hood in closed position, install grille surround and position on hood and install prevailing torque nuts.

27. Position grille into place and install M8 Tone® bolts.

28. Remove wheel chocks.

 

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Chronology :

  • 01/15/2023 – Navistar Engineering received communication of this issue from Service Engineering.
  • 01/15/2013 – Navistar Engineering initiates an investigation into grille surround supplier.
  • 01/26/2023 – Navistar Engineering and supplier reviews the validation results from when the
    attachment methods of the mounting brackets to the surround changed from spot welding to adhesive.
  • 02/13/2023 – An analysis of a loose grille surround was completed and determined to have insufficient plating of all eight mounting brackets.
  • 02/14/2023 – Navistar Engineering and Product Compliance meet to review the issue and determine the possible vehicle level impact to the HX series trucks.
  • 2/24/2023 – Navistar finishes a study of warranty claims to determine how widespread this issue may be.
  • 03/08/2023 – Engineering and Product Compliance finalize the suspect population.
  • 03/09/2023 – Navistar declares a Safety Recall.
  • 03/24/2023 – Navistar removes vehicles quarantined at the plants from the suspect population.

 

Warranty Claim Summary

VINs Vehicle Prod Date Warranty Claim Date
LN305983 05/07/2019 05/26/2021
LN146563 09/03/2019 12/20/2021
MN632819 09/08/2020 02/24/2022
LN317203 06/24/2019 05/27/2022
NN303289 11/17/2021 08/19/2022
NN609502 03/09/2021 09/29/2022
MN548866 01/30/2020 02/01/2023

 


5 Affected Products

Vehicle

MAKE MODEL YEAR
INTERNATIONAL HX 2020-2024

 


9 Associated Documents

Defect Notice 573 Report

RCLRPT-23V170-3411.PDF 214.347KB

 


Recall Acknowledgement

RCAK-23V170-2212.pdf 646.169KB

 


Recall 573 Report – March 24, 2023

RCLRPT-23V170-1273.PDF 214.815KB

 


Remedy Instructions and TSB

RCRIT-23V170-9338.pdf 2140.196KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-23V170-3125.pdf 73.748KB

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Recall 573 Report – October 25, 2023

RCLRPT-23V170-8274.PDF 215.025KB

 


Remedy Instructions and TSB

RCRIT-23V170-2414.pdf 306.076KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V170-1420.pdf 43.922KB

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Recall Quarterly Report #1, 2023-4

RCLQRT-23V170-3054.PDF 211.269KB

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V170&docType=RCL

 


 

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