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April 6, 2023 NHTSA CAMPAIGN NUMBER: 23V248000
HVAC Blower Motor Circuit May Overheat
An overheated electrical circuit can increase the risk of a fire.
NHTSA Campaign Number: 23V248
Manufacturer Navistar, Inc.
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 44,887
Summary
Navistar, Inc. (Navistar) is recalling certain 2016-2020 International DuraStar, WorkStar, 2017-2018 International TranStar, 2018 International ProStar, 2020 International HV, MV, and 2018 IC Bus HC Commercial buses. The heating, ventilation, and air-conditioning (HVAC) blower motor circuit may have an insufficient wiring terminal that can overheat.
Remedy
Dealers will replace the HVAC blower motor load circuit wiring terminal, free of charge. Owner notification letters are expected to be mailed June 5, 2023. Owners may contact Navistar’s customer service at 1-800-448-7825. Navistar’s number for this recall is 23510.
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.
Navistar Recall 23510 Chronology of Events
- 01/12/2022 Navistar Product Integrity Group ( PIG ) inspects a vehicle that experienced a fire that consumed most of the passenger side fuse panel and HVAC area. Due to extensive damage, cause could not be determined. Focus was placed on HVAC blower motor as a potential cause at the time.
- 03/03/2022 Navistar PIG receives communication of a second vehicle at same customer with an HVAC blower motor fuse that melted the PDC at the blower motor load circuit.
- 04/08/2022 thru 06/13/2022 Navistar Engineering, Navistar Field Service and dealer develop a repair plan for this second vehicle that was reported. This included replacing the damaged section for the PDM, installing new terminals for terminals that showed sign of being damaged and taking an amp draw on the blower motor and report the results to Navistar Engineering. At this time, this was considered an isolated event due to the single customer application.
- 06/14/2022 Navistar PIG is notified by a dealer of a third vehicle from same customer.
- 06/18/2022 Navistar completes warranty review and found 65 claims on 12 years of production received between 07/02/2015 thru 08/30/2021 for the blower motor load side wire terminal in the PDM. 30 of the claims mentioned melting at the A4 cavity for the blower motor and 35 claims stated that the terminal had a spread terminal. No thermal events were found. Focus was now placed on understanding cause of spread terminals.
- 07/27/2022 Navistar Engineering and Navistar Field Service performs field inspections of vehicles where this single customer s third vehicle was located. This third vehicle had a small thermal event that melted the PDM at the blower motor circuit and caused some damage to the Instrument Panel above the PDM. Two additional customer vehicles were inspected at this time, including extensive testing measuring voltage and amperage of the blower motor and measuring temperature of the terminal in question for at least one hour. No performance anomalies were found.
- 08/01/2022 Navistar Engineering receives the PDM blower motor fuse block from the third vehicle from the customer for review.
- 09/26/2022 Navistar Compliance receives communication from the field of two additional vehicles from the same customer that had PDMs with thermal damage at the blower motor fuse block area. All thermal events as of this date were with one customer.
- 09/26/2022 Navistar Compliance, Engineering and Field support meet to review data collected from field investigations.
- 08/01/2022 thru 11/11/2022 Navistar Engineering examines and analyzes the PDM from the third vehicle and arranges to send this PDM to a third-party for analysis.
- 02/01/2023 Navistar receives CT scan results from the third-party for the third vehicle s PDM that determined the overheated terminal was of low-current thin material and not capable of meeting the continuous electrical current load requirement of the blower motor load side circuit.
- 02/01/2023 Navistar Field Service reports that the customer s trucks have been repaired and parts are available for analysis. Navistar Engineering requests the PDM blower motor fuse block area parts from the 4th and 5th vehicles that had a thermal event be returned to Navistar for analysis.
- 02/23/2023 Navistar Engineering investigates to determine if any deviations were written allowing a different terminal to be used and found that Navistar did not authorize any deviations.
- 02/28/2023 Navistar Engineering sends the two additional PDM blower motor fuse blocks from the 4th and 5th vehicles that had a thermal event to third-party for CT Scan analysis.
- 02/28/2023 Navistar completes a second warranty review and found 3 additional warranty claims for a total of 68 claims received between 07/02/2015 thru 02/03/2023 for the blower motor load side wire terminal in the PDM. 30 of the claims mentioned melting at the A4 cavity for the blower motor and 38 claims stated that the terminal had a spread terminal. No thermal events were found.
- 03/01/2023 Navistar Engineering and Compliance review engineering specifications for its terminal ratings.
- 03/06/2023 Navistar Engineering and Compliance meet to share the results of the CT scan analyses performed on the three PDM blower motor fuse blocks that had a thermal event. The team continues to work with the supplier of the assembled PDM to determine if they were built with the incorrect terminal.
- 03/08/2023 Navistar Engineering requests the Supplier to provide data for terminal usage on PN 3599501C1.
- 03/10/2023 Navistar Engineering investigates vehicles at the Chicago Used Truck Center and finds 5 out of 19 potential suspect trucks to have low current terminal (1 with evidence of melting).
- 03/14/2023 Navistar Engineering and supplier meet to review initial data of terminal usage and requests that the Supplier investigate how the incorrect terminal was installed.
- 03/15/2023 through 3/17/2023 Navistar Supplier Quality visits supplier facilities and reviews investigation results, blower motor circuit details, containment, and control practices.
- 03/17/2023 Navistar Supplier Quality performs on-site review at supplier of Supplier s process and controls for wire terminal selection.
- 03/17/2023 Supplier provides preliminary potential suspect population of PDMs that may have been assembled with the low current terminal.
- 3/24/2023 Supplier provides complete traceability of vehicles that received PDMs with low current terminals in the HVAC fuse block.
- 03/30/2023 Navistar finalizes the suspect population and declares a Safety Recall.
16 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| IC BUS | HC | 2018 |
| INTERNATIONAL | DURASTAR | 2016-2020 |
| INTERNATIONAL | HV | 2020 |
| INTERNATIONAL | MV | 2020 |
| INTERNATIONAL | PROSTAR | 2018 |
| INTERNATIONAL | TRANSTAR | 2017-2018 |
| INTERNATIONAL | WORKSTAR | 2016-2020 |
5 Associated Documents
Defect Notice 573 Report
RCLRPT-23V248-1760.PDF 219.301KB
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Navistar – Chronology – April 2023
RMISC-23V248-3375.pdf 47.792KB
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Recall Acknowledgement
RCAK-23V248-1163.pdf 645.984KB
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Recall 573 Report – April 6, 2023
RCLRPT-23V248-3608.PDF 219.301KB
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Recall 573 Report – April 12, 2023
RCLRPT-23V248-3999.PDF 219.289KB
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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=23V248&docType=RCL
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-248 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : APR 06, 2023 NHTSA Recall No. : 23V-248 Manufacturer Recall No. : 23510 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 44,887 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2016-2020 International DuraStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 32,692 DuraStar model trucks in the suspect population Production Dates : SEP 03, 2015 – DEC 20, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2016-2020 International WorkStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 12,028 WorkStar model trucks in the suspect population. Production Dates : SEP 02, 2015 – NOV 28, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2017-2018 International TranStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 157 TranStar model trucks in the suspect population. Production Dates : JAN 19, 2016 – JUL 06, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2018-2018 International ProStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 4 ProStar model trucks in the suspect population. Production Dates : MAY 03, 2017 – AUG 10, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 3 HV series trucks in the suspect population. Production Dates : FEB 08, 2019 – FEB 08, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 6 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 2 MV series trucks in the suspect population. Production Dates : AUG 14, 2019 – OCT 09, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 7 : 2018-2018 IC Bus HC Commercial bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There is one HC commercial bus in the suspect population. Production Dates : JUN 29, 2017 – JUN 29, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The HVAC blower motor circuit on the load side of the circuit breaker in the PDM may have been assembled with a wire terminal that does not meet the continuous electrical current load requirement. This can cause over-heating that may melt the plastic material of the terminal block for the HVAC circuit and cause subsequent thermal damage of the surrounding area of the PDM and or dash panels. Part 573 Safety Recall Report 23V-248 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A wiring terminal that does not meet the continuous electrical current load requirement of the HVAC blower motor circuit can cause a thermal event that may result in property damage to the vehicle and/or personal injury or death to the vehicle operator. Description of the Cause : The supplier did not use the Navistar specified wire terminal for the HVAC blower motor load circuit. A terminal which fit physically into the terminal block but could not meet the continuous electrical current load requirement was substituted to a different part number. In the supplier’s system it indicated that both part numbers could be used as they were the same style and for the same gauge wire. The supplier did not take into account the continuous amperage load capability required of the HVAC blower motor circuit. Identification of Any Warning that can Occur : None. Involved Components : Component Name 1 : Wire terminal Component Description : Terminal, Electrical, Cable Component Part Number : 3536590C1 Supplier Identification : Component Manufacturer Name : MSSL Wiring System Inc. (MSSL) Address : Prolongación Isidro Lopez Zertuche # 1950 Colonia Capellania Ramos Arizpe Coahuila, CP Foreign States 25900 Country : Mexico Chronology : The chronology exceeds the 2000-character limit and will be submitted as a miscellaneous document. Part 573 Safety Recall Report 23V-248 Page 6 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 the HVAC blower motor load circuit wiring terminal with correct terminal pigtail that meets the continuous electrical current load requirement and all fuse blocks found with thermal damage. • 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 wire terminal meets the continuous electrical current load requirement where the recalled wire terminal does not. Identify How/When Recall Condition was Corrected in Production : 01/06/2020 – Navistar begins use of a redesigned PDM cab harness assembly. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 06/05/2023. Planned Dealer Notification Date : JUN 05, 2023 – JUN 05, 2023 Planned Owner Notification Date : JUN 05, 2023 – JUN 05, 2023 * NR – Not Reported
**************************************************************************************************************
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-248 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : APR 06, 2023 NHTSA Recall No. : 23V-248 Manufacturer Recall No. : 23510 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 44,887 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2016-2020 International DuraStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 32,692 DuraStar model trucks in the suspect population Production Dates : SEP 03, 2015 – DEC 20, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2016-2020 International WorkStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 12,028 WorkStar model trucks in the suspect population. Production Dates : SEP 02, 2015 – NOV 28, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2017-2018 International TranStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 157 TranStar model trucks in the suspect population. Production Dates : JAN 19, 2016 – JUL 06, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2018-2018 International ProStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 4 ProStar model trucks in the suspect population. Production Dates : MAY 03, 2017 – AUG 10, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 3 HV series trucks in the suspect population. Production Dates : FEB 08, 2019 – FEB 08, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 6 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 2 MV series trucks in the suspect population. Production Dates : AUG 14, 2019 – OCT 09, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 7 : 2018-2018 IC Bus HC Commercial bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There is one HC commercial bus in the suspect population. Production Dates : JUN 29, 2017 – JUN 29, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The HVAC blower motor circuit on the load side of the circuit breaker in the PDM may have been assembled with a wire terminal that does not meet the continuous electrical current load requirement. This can cause over-heating that may melt the plastic material of the terminal block for the HVAC circuit and cause subsequent thermal damage of the surrounding area of the PDM and or dash panels. Part 573 Safety Recall Report 23V-248 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A wiring terminal that does not meet the continuous electrical current load requirement of the HVAC blower motor circuit can cause a thermal event that may result in property damage to the vehicle and/or personal injury or death to the vehicle operator. Description of the Cause : The supplier did not use the Navistar specified wire terminal for the HVAC blower motor load circuit. A terminal which fit physically into the terminal block but could not meet the continuous electrical current load requirement was substituted to a different part number. In the supplier’s system it indicated that both part numbers could be used as they were the same style and for the same gauge wire. The supplier did not take into account the continuous amperage load capability required of the HVAC blower motor circuit. Identification of Any Warning that can Occur : None. Involved Components : Component Name 1 : Wire terminal Component Description : Terminal, Electrical, Cable Component Part Number : 3536590C1 Supplier Identification : Component Manufacturer Name : MSSL Wiring System Inc. (MSSL) Address : Prolongación Isidro Lopez Zertuche # 1950 Colonia Capellania Ramos Arizpe Coahuila, CP Foreign States 25900 Country : Mexico Chronology : The chronology exceeds the 2000-character limit and will be submitted as a miscellaneous document. Part 573 Safety Recall Report 23V-248 Page 6 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 the HVAC blower motor load circuit wiring terminal with correct terminal pigtail that meets the continuous electrical current load requirement and all fuse blocks found with thermal damage. • 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 wire terminal meets the continuous electrical current load requirement where the recalled wire terminal does not. Identify How/When Recall Condition was Corrected in Production : 01/06/2020 – Navistar begins use of a redesigned PDM cab harness assembly. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 06/05/2023. Planned Dealer Notification Date : JUN 05, 2023 – JUN 05, 2023 Planned Owner Notification Date : JUN 05, 2023 – JUN 05, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-248 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : APR 12, 2023 NHTSA Recall No. : 23V-248 Manufacturer Recall No. : 23510 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 44,887 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2016-2020 International DuraStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 32,692 DuraStar model trucks in the suspect population Production Dates : SEP 03, 2015 – DEC 20, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2016-2020 International WorkStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 12,028 WorkStar model trucks in the suspect population. Production Dates : SEP 02, 2015 – NOV 28, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2017-2018 International TranStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 157 TranStar model trucks in the suspect population. Production Dates : JAN 19, 2016 – JUL 06, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2018-2018 IC Bus HC Commercial bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There is one HC commercial bus in the suspect population. Production Dates : JUN 29, 2017 – JUN 29, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 3 HV series trucks in the suspect population. Production Dates : FEB 08, 2019 – FEB 08, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-248 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 6 : 2020-2020 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 factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 2 MV series trucks in the suspect population. Production Dates : AUG 14, 2019 – OCT 09, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 7 : 2018-2018 International ProStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with factory installed Heating/Ventilating/Air Conditioning (HVAC) system. • The inclusive dates of manufacture were determined by when Navistar began use of Power Distribution Center (PDC) main cab harness with low current terminal in HVAC blower motor circuit through when Navistar began use of PDC main cab harness with correct high current terminal in HVAC blower motor circuit. • The vehicles in the suspect population were built with PDC main cab harness with low current terminal in HVAC blower motor circuit and all similar vehicles not subject to this recall were built with PDC main cab harness with correct high current terminal in HVAC blower motor circuit. There are 4 ProStar model trucks in the suspect population. Production Dates : MAY 03, 2017 – AUG 10, 2017 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The HVAC blower motor circuit on the load side of the circuit breaker in the PDM may have been assembled with a wire terminal that does not meet the continuous electrical current load requirement. This can cause over-heating that may melt the plastic material of the terminal block for the HVAC circuit and cause subsequent thermal damage of the surrounding area of the PDM and or dash panels. Part 573 Safety Recall Report 23V-248 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : A wiring terminal that does not meet the continuous electrical current load requirement of the HVAC blower motor circuit can cause a fire that may result in property damage to the vehicle and/or personal injury or death to the vehicle operator. Description of the Cause : The supplier did not use the Navistar specified wire terminal for the HVAC blower motor load circuit. A terminal which fit physically into the terminal block but could not meet the continuous electrical current load requirement was substituted to a different part number. In the supplier’s system it indicated that both part numbers could be used as they were the same style and for the same gauge wire. The supplier did not take into account the continuous amperage load capability required of the HVAC blower motor circuit. Identification of Any Warning that can Occur : None. Involved Components : Component Name 1 : Wire terminal Component Description : Terminal, Electrical, Cable Component Part Number : 3536590C1 Supplier Identification : Component Manufacturer Name : MSSL Wiring System Inc. (MSSL) Address : Prolongación Isidro Lopez Zertuche # 1950 Colonia Capellania Ramos Arizpe Coahuila, CP Foreign States 25900 Country : Mexico Chronology : The chronology exceeds the 2000-character limit and will be submitted as a miscellaneous document. Part 573 Safety Recall Report 23V-248 Page 6 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 the HVAC blower motor load circuit wiring terminal with correct terminal pigtail that meets the continuous electrical current load requirement and all fuse blocks found with thermal damage. • 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 wire terminal meets the continuous electrical current load requirement where the recalled wire terminal does not. Identify How/When Recall Condition was Corrected in Production : 01/06/2020 – Navistar begins use of a redesigned PDM cab harness assembly. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 06/05/2023. Planned Dealer Notification Date : JUN 05, 2023 – JUN 05, 2023 Planned Owner Notification Date : JUN 05, 2023 – JUN 05, 2023 * NR – Not Reported
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