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

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-170 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : MAR 16, 2023 NHTSA Recall No. : 23V-170 Manufacturer Recall No. : 23507 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 5,808 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2024 International HX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by the models of the vehicle, HX520 and HX620. • The inclusive dates of manufacture were determined by when there was a design change to the grille surround. • The vehicles in the suspect population were built with a steel grille surround; all other models use a non-metallic grille surround. There are 5808 HX series trucks in the suspect population. Production Dates : MAR 13, 2019 – FEB 28, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The grille surround is attached to eight (8) mounting brackets by a bonding material. Over time, corrosion can develop between the two dissimilar metal components and cause the bonding material to lose adhesion, resulting in the grille surround coming loose one bracket at a time and could cause the grille surround to separate from the truck. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A grille surround that separates from the vehicle 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. To date, there have been no reported crashes for this issue. Description of the Cause : Insufficient plating in the area where the eight (8) mounting brackets are Part 573 Safety Recall Report 23V-170 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 attached to the grille surround results in a small area of bare steel susceptible to corrosion over time. Identification of Any Warning that can Occur : Driver would hear the grille surround rattling when the vehicle is in operation and should notice that grille surround is not flush against the hood during a pre-trip walk around inspection. Involved Components : Component Name 1 : Grille Surround Component Description : Surround Assembly Component Part Number : International P/N 4059254C95 and 4160590C93 Supplier Identification : Component Manufacturer Name : Lincoln Industries Address : 600 West E Street Lincoln Nebraska 68522 Country : United States 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. Part 573 Safety Recall Report 23V-170 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : • The remedy will involve replacing grille surround on 8,120 units plus those that will be built prior to containment. • 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. • An Interim notice will be mailed to affected customers instructing them to periodically inspect their grille surround and repair if necessary. How Remedy Component Differs from Recalled Component : The remedy grille surround will be assembled using a new process to attach the brackets. Identify How/When Recall Condition was Corrected in Production : 03/15/2023 – Navistar contains the issue in manufacturing by issuing a stop ship order. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 05/15/2023. Planned Dealer Notification Date : MAY 15, 2023 – MAY 15, 2023 Planned Owner Notification Date : MAY 15, 2023 – MAY 15, 2023 * NR – Not Reported

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-170 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : MAR 24, 2023 NHTSA Recall No. : 23V-170 Manufacturer Recall No. : 23507 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 5,769 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2020-2024 International HX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by the models of the vehicle, HX520 and HX620. • The inclusive dates of manufacture were determined by when there was a design change to the grille surround. • The vehicles in the suspect population were built with a steel grille surround; all other models use a non-metallic grille surround. There are 5769 HX series trucks in the suspect population. Production Dates : MAR 13, 2019 – FEB 28, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The grille surround is attached to eight (8) mounting brackets by a bonding material. Over time, corrosion can develop between the two dissimilar metal components and cause the bonding material to lose adhesion, resulting in the grille surround coming loose one bracket at a time and could cause the grille surround to separate from the truck. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A grille surround that separates from the vehicle 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. To date, there have been no reported crashes for this issue. Description of the Cause : Insufficient plating in the area where the eight (8) mounting brackets are Part 573 Safety Recall Report 23V-170 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 attached to the grille surround results in a small area of bare steel susceptible to corrosion over time. Identification of Any Warning that can Occur : Driver would hear the grille surround rattling when the vehicle is in operation and should notice that grille surround is not flush against the hood during a pre-trip walk around inspection. Involved Components : Component Name 1 : Grille Surround Component Description : Surround Assembly Component Part Number : International P/N 4059254C95 and 4160590C93 Supplier Identification : Component Manufacturer Name : Lincoln Industries Address : 600 West E Street Lincoln Nebraska 68522 Country : United States 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. Seven warranty claims received on 05/26/2021, 12/20/2021, 02/24/2022, 05/27/2022, 08/19/2022, 09/29/2022/ and 02/01/2023 were found to have concerns, there are no Field Reports, Customer Complaints or death/injury claims found for this issue. For additional warranty details, refer to chart at end of chronology. • 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 Part 573 Safety Recall Report 23V-170 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 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 Description of Remedy : Description of Remedy Program : • The remedy will involve replacing grille surround on 5,769 units plus those that will be built prior to containment. • 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. • An Interim notice will be mailed to affected customers instructing them to periodically inspect their grille surround and repair if necessary. How Remedy Component Differs from Recalled Component : The remedy grille surround will be assembled using a new process to attach the brackets. Identify How/When Recall Condition was Corrected in Production : 03/15/2023 – Navistar contains the issue in manufacturing by issuing a stop ship order. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 05/15/2023. Planned Dealer Notification Date : MAY 15, 2023 – MAY 15, 2023 Planned Owner Notification Date : MAY 15, 2023 – MAY 15, 2023 * NR – Not Reported

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