Steering Gear Assembled Incorrectly – 2022-2023 International HX, HV, LoneStar, LT, MV, RH, IC Bus TC Commercial Bus, & 2022 International WorkStar

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June 16, 2022 NHTSA CAMPAIGN NUMBER: 22V428000

Steering Gear Assembled Incorrectly

A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V428

Manufacturer Navistar, Inc.

Components STEERING

Potential Number of Units Affected 33,655

 

Summary

Navistar, Inc. (Navistar) is recalling certain 2022-2023 International HX, HV, LoneStar, LT, MV, RH, IC TC Commercial Bus, and 2022 International WorkStar vehicles. The steering gears may have been assembled incorrectly, which can cause the gear to fracture.

 

Remedy

Dealers will inspect the steering gear serial numbers, and replace the steering gears as necessary, free of charge. Interim owner notification letters were mailed August 18, 2022. Remedy parts are expected to become available in mid-October 2022. Owners may contact Navistar customer service at 1-800-448-7825. Navistar’s number for this recall is 22513.

 

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.

 


SERVICE PROCEDURE

22513

October, 2022

 

SUBJECT: SAFETY RECALL 

Steering Gear on certain 2022 and 2023 IC Bus® CE, FE Chassis, SFC and TC commercial buses, International® WorkStar® and Prostar® model trucks and HV™, HX®, LT®, MV™, RH™, and Lonestar® series trucks built 06/01/2021 through 06/07/2022 built with R. H. Sheppard HD94E, M100P, M110P, HD94P, XD120P, MD83P, SD110P, M83P, M90P, or M80P model steering gears

 

CUSTOMER LETTER

Print ready (PDF file) copy of the Customer Letter

 

DEFECT DESCRIPTION

The steering gears may have been assembled with less than the required input shaft ball bearings and can result in a fracture of the input shaft and loss of steering. A loss of steering increases the risk of a vehicle crash.

 

MODELS INVOLVED

This safety recall involves certain 2022 and 2023 IC Bus® CE, FE Chassis, SFC and TC commercial buses, International® WorkStar® and Prostar® model trucks and HV™, HX®, LT®, MV™, RH™, and Lonestar®seriestrucks built06/01/2021 thru 06/07/2022 built with R.H. Sheppard HD94E, M100P, M110P, HD94P, XD120P,

MD83P, SD110P, M83P, M90P, or M80P model steering gears.

 

ELIGIBILITY

This procedure applies ONLY to vehicles marked in the International® Service Portal5M with Safety Recall 22513. Also complete any other open campaigns listed on the Service Portal at this time.

 

PARTS INFORMATION

NOTE: New trucks in dealer inventory that are found to have a suspect steering gear, must be repaired using a steering gear for non – Delivered To User (DTU) vehicle and not a recall part number.

 

NOTE: If your location has any steering gears in inventory, please refer to the R.H. Sheppard link later in this procedure to determine inventory steering gear status.

 

NOTE: Do not pre-order steering gears for inventory as only 1,600 of the 45,000 vehicles will require a replacement. Some customers may experience a higher SUSPECT percentage result.

 

NOTE: Any suspect steering gear removed are required to be returned to Product Review Center per warranty standard procedures.

 

See table at end of document for specific parts information.

 

SERVICE PROCEDURE

WARNING! To prevent personal injury and/ or death, or damage to property, park vehicle on hard flat surface, turn the engine off, set the parking brake and install wheel chocks to prevent the vehicle from moving in either direction.

 

WARNING! To prevent personal injury and / or death, always wear safe eye protection when performing vehicle maintenance.

 

WARNING! To prevent personal injury and/ or death, or damage to property, allow engine/ vehicle components to cool before servicing.

 

WARNING! To prevent personal injury and/ or death, or damage to property, keep flames or sparks away from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel explosive gases.

 

STEERING GEAR INSPECTION

  1. Park vehicle on flat surface.

 

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

 

  1. Turn vehicle ignition to Key OFF position.

 

  1. Install wheel chocks.

 

  1. Unlatch and open hood to access steering gear.

 

NOTE: The steering gear serial number is located on the steering gear housing at the bottom of the sector shaft outlet. The wheels may need to be turned for proper viewing. Additionally, a small portion of gears may have the serial number at the top of the sector shaft outlet.

 

NOTE: The steering gear serial number is a two-digit year followed by an alpha numeric month Example: 21E (2021 May).

 

NOTE: If the serial number and / or part number are illegible due to paint, a flat head screwdriver, wire brush, or emery cloth may be used to lightly remove paint where the numbers are located.

 

  1. Record the entire steering gear serial Use the R.H. Sheppard link below to determine if the gear needs to be replaced.

Sheppard Steering Gear Classification Tool (rhsheppard.com)

 

a. Select Navistar, International from the Select Vehicle Make drop­ down table (Figure 2, Item 1).

b. Enter the serial number (Figure 2, Item 3) and select Search (Figure 2, Item 4).

NOTE: Suspect serial numbers will have year/ month range of 21C025XX through 22B041.XX.

c. If the result is Good or Serial Number Entered Is Outside The Date Range, (Figure 2, Item 2), replacement is not required. Proceed to Step 23.

d. If the result is Not Found (Figure 2, Item 2), follow instructions on R.H. Sheppard website.

e. If the result is Suspect (Figure 2, Item 2), the steering gear will require replacement. Proceed to Step 7.

 

STEERING GEAR REPLACEMENT

NOTE: Because the steering gear is suspect and has not failed, filter change and fluid flush are NOT included in steering gear replacement.

 

For further reference, please refer to the link below:

 

R.H. Sheppard Instructions for Installing Steering Gears

 

  1. Place drain pan under vehicle.

 

  1. Remove power steering return line from steering gear and drain fluid.

 

  1. Disconnect power steering pressure line from steering gear.

 

NOTE: Do not rotate steering wheel once the intermediate shaft has been disconnected from the steering gear.

 

  1. Remove pinch bolt and nut from steering gear input shaft and disconnect steering column. Discard pinch bolt, nut, and washers.

 

  1. Remove cotter pin and castellated nut from drag link and disconnect drag link from pitman arm. Discard cotter pin.

 

  1. Support steering gear and remove steering gear mounting bolts and Save bolts and nuts for reuse.

 

NOTE: Record the clocking of both hydraulic fittings and pitman arm necessary for them to be correctly installed on new steering gear.

 

  1. With the steering gear on a clean work bench, transfer the hydraulic fittings and align the timing marks when installing the pitman arm to new steering gear.

 

Gear to Frame Mounting Bolt Size Socket Size Lb-ft N·m
M12 19mm 95 – 105 lb-ft 129 – 142 N·m
M16 24mm 217 – 240 lb-ft 294-325 N·m
M20 30mm 413 -461 lb-ft 560-625 N·m
15/16 in 15/16 in 220 – 240 lb-ft 298-325 N·m
3/4 in 1 1/8 in 330 – 370 lb-ft 447 -502 N·m

Table 1 Gear to Frame B0 ltT orque

 

  1. Position new steering gear into place and install mounting bolts. Using a torque wrench, tighten bolts to proper torque specification listed in Table 1.

 

  1. Reconnect drag link to pitman arm; install castellated nut and tighten nut to 120 – 170 lb-ft (163 – 230 N·m), and install new cotter pin.

 

NOTE: The pitman arm to steering gear bolt should be tightened to torque value stamped on face of retainer.

 

  1. Torque pitman arm retainer to torque value stamped onto face of If two notches of locking washer do not align with notches in the retainer continue tightening the retainer until they align. Bend retaining tabs into the notches of the retainer.

 

  1. Reconnect steering column shaft to steering gear input shaft, install new pinch bolt, washers, and Using a torque wrench, tighten bolt to 68 – 76 lb-ft (92 – 103 N·m).

 

  1. Install power steering pressure and return Tighten pressure line fitting and return line hose clamp.

 

  1. Fill power steering reservoir.

 

  1. Start engine, bleed system, and inspect for leaks.

 

CAUTION! Failure to set the adjust of the relief plungers may result in damage to the steering system. Plunger must be set or adjusted whenever a steering gear is replaced.

 

  1. Set the AUTO relief plungers or adjust the manual relief plungers to obtain the proper wheel cut.

 

  1. Turn vehicle ignition to Key OFF position.

 

  1. Top off power steering fluid.

 

  1. Close and latch hood.

 

  1. Remove wheel chocks.

 

END OF SERVICE PROCEDURE

 

PARTS INFORMATION 

Part Number Part Description Quantity
Appropriate Fluid P/N by Vehicle Fluid; Power Steering As needed if gear is replaced
4065729C1 Bolt, Hex HD, 7/16-20 UNF Grade 8 1 if Qear is replaced
4066697C1 Nut, Hex Lock, 7/16-20, Grade 8 1 if Qear is replaced
25846R1 Washer; 7/16 Hardened 2 if Qear is replaced
137214 Pin; Cotter 1/8 X 1 3/4 Inch LQ. 1 if Qear is replaced

 

NOTE: Using the International Parts System, verify the steering gear part number that the vehicle was built with. Using the correct part number refer to the table below to determine the correct steering gear part number to order.

 

NOTE: Submit all steering gear orders as a Critical Order Unit Down with VIN number.

 

NOTE: If a Steering Gear for vehicles without a DTU date is used on a vehicle with a DTU date, the parts cost will be adjusted to the Recall Part Number.

 

Production Steering Gear PN Steering Gear Description Steering Gear for Non DTU’d Vehicles Navistar Recall Part Number
4200662C92 HD94EC3 4200662C92 and 4218673C5 4200662C92 and 4218673C5
3844903C92 HD94PAH3 3844903C92 8900302R91
3596197C92 HD94PD3 3596197C92 8900315R91
3830944C91 HD94PG3 3830944C91 8900324R91
3804386C92 HD94PQ3 3804386C92 8900304R91
3537280C91 M100PKH3 3537280C91 8900316R91
3554374C91 M100PMR3 3554374C91 8900308R91
3554373C91 M100PMT3 3554373C91 8900303R91
3558088C91 M100PMX3 3558088C91 8900307R91
3606529C91 M100PQM3 3606529C91 8900310R91
3812815C91 M100PRL3 3812815C91 8900317R91
3858121C91 M100PSY3 3858121C91 8900319R91
3885826C91 M100PTD3 3885826C91 8900305R94
3886363C91 M100PTH3 3886363C91 8900311R91
3900547C91 M100PTQ3 3900547C91 8900323R91
4041605C91 M100PUS3 4041605C91 8900313R91
3602517C91 M110PJE3 3602517C91 8900312R91
3846858C91 M110PMV3 3846858C91 8900309R91
3846865C91 M110PMW3 3846865C91 8900314R91
3679944C92 M110PRR3 3679944C92 8900318R91
1664770C91 M90PAE1 1664770C91 8900320R91
3919567C93 MD83PAD3 3919567C93 8900321R91
3867486C92 MD83PT3 3867486C92 8900322R91

 


Chronology :

  • 05/23/2022 – RH Sheppard notifies Navistar they have filed a 573 report to NHTSA related to several steering gear models.
  • 05/25/2022 – RH Sheppard meets with Navistar Compliance, Engineering, and Quality to determine the impact to International trucks and IC buses; determine failure mode and potential root cause.
  • 06/01/2022 – Navistar Compliance and Engineering narrow the scope of vehicle configurations built with potential suspect steering gears.
  • 06/02/2022 – Navistar Compliance Committee meets to discuss initial suspect population, potential root cause and failure mode. The Committee outlines next steps necessary to contain and inspect suspect vehicles and inventory at Navistar’s Parts Distribution Centers (PDCs).
  • 06/08/2022 – Navistar quarantines 4,952 vehicles at their assembly plants for inspection and 85 steering gears were placed on quality hold at the PDCs.
  • 06/09/2022 – Bendix provides Navistar a list of 1,590 suspect steering gear serial numbers that they believe may contain a smaller than normal number of recirculating balls.
  • 06/09/2022 – Navistar Compliance Committee meets to determine final suspect population, review suspect steering gear serial numbers, potential field remedy, and declares a Safety Recall.

 


15 Affected Products

Vehicles

MAKE MODEL YEAR
IC BUS TC 2022-2023
INTERNATIONAL HV 2022-2023
INTERNATIONAL HX 2022-2023
INTERNATIONAL LONESTAR 2022-2023
INTERNATIONAL LT 2022-2023
INTERNATIONAL MV 2022-2023
INTERNATIONAL RH 2022-2023
INTERNATIONAL WORKSTAR 2022

 


6 Associated Documents

Defect Notice 573 Report

RCLRPT-22V428-3949.PDF 218.332KB

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Recall Acknowledgement

RCAK-22V428-1555.pdf 646.108KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V428-2733.pdf 31.709KB

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Remedy Instructions and TSB

RCRIT-22V428-2121.pdf 262.279KB

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Remedy Instructions and TSB

RCRIT-22V428-1478.pdf 2790.108KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V428-9522.pdf 72.252KB

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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=22V428&docType=RCL

 


 

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