NHTSA ID Number: 10115352
Manufacturer Communication Number: IK1201258
TSB/Document Date: 2017-08-16
Summary
Catastrophic DOC and DPF Failures
IK1201258 Catastrophic DOC and DPF Failures
Page 1 of 11
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IK1201258
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Availability: ISIS, Bus ISIS
Revision: 5
Major
System:
ENGINES
Created:
Current
Language:
English
Last
4/21/2016
Modified:
Other
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Author:
1/20/2015
Allan
Hertko
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Title : Catastrophic DOC and DPF Failures
Applies To : All Navistar
Engines
CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
4/20/2016- Updated article Step 9 and figure 10
10/29/2015 - Included information for catastrophic DPF failures as well (merged with IK1201251)
9/14/2015 - Fixed link to V8 DPF & DOC Catastrophic Failure Performance Assessment Sheet
1/20/2015 - Initial Article Release.
3/2/2015 - Added V8 Diagnostic info, DOC cracked inlet, DOC oil soaked & updated required claim information section.
DESCRIPTION
Diesel Oxidation Catalysts (DOCs) and/or Diesel Particulate Filters (DPFs) that have catastrophically failed do not require an
iApproval case file as long as it is only the DOC/DPF failure within the last 24 months.
This article details the following:
• What is considered a catastrophic failure
• What information must be included with the warranty claim
• What post repair data should be reviewed by the technician to correct the root cause of the failure and verify the repair
Catastrophic Failure
The following failure modes are considered catastrophic:
- Substrate separation
Melted DOC/DPF
- DOC cracked inlet flange
- Oil soaked DOC/DPF
- Excessive substrate shifting
Broken Bung
Black smoke
The following are NOT considered catastrophic failures:
- Moderate substrate shifting
Stripped threads
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IK1201258 Catastrophic DOC and DPF Failures
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Each of the seven failure modes are detailed below.
Figure 1: DOC Substrate separation
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 2: DPF Substrate separation
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 3: Melted DOC
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 4: Melted DPF
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
Figure 5: DOC Cracked Inlet Flange
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 6: Oil Soaked DOC
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
Figure 7: Oil Soaked DPF
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 8: Excessive substrate shifting
Moderate substrate shifting is not considered a catastrophic failure. Excessive shifting is defined as
enough movement to damage sensors. Please reference the aftertreatment diagnostic manual for additional
information on brick shifting.
Figure 9: Broken bung
Pictured above are broken bungs. If broken or damaged unable to remove DPFDP tube the assembly must be
replaced. Stripped threads are not considered a catastrophic failure. Reference the aftertreatment diagnostic
manual (P.225) for repair process.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 10: Black smoke
If continuous black smoke is seen exiting the tailpipe during one
of the following tests below then the DPF has catastrophically
failed.
- Snap Accel Test (IK0700032)
- During zero - highway speed (100% engine load)
- Pulling a load or hill
Claim Information
NOTE: Claims lacking the required details can be rejected.
All non-iApproval cases must have the following information:
1. A clear inlet & outlet photo of the catastrophically failed DOC/DPF as shown in figures 110 above. Also see WPL2800083.
2. A vehicle health report taken prior to the repair.
3. A detailed explanation of what the root cause of failure was if applicable should be included as shown in figures 11
and 12 below, however if unable to determine the root cause ensure unit meets all performance specifications per its
diagnostic manual before releasing.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 11: Melted DOC
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
Description: Followed Aftertreatment Diagnostic Manual 0000003081 symptom 3 to step 4,
identified DOC was melted. Replaced DOC, followed to step 6 to verify system operation
found unit has a cracked injector tip that is the root cause of the DOC melting. Completed all
repairs and verified unit meets all operating specifications listed in the engine diagnostic
manual.
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IK1201258 Catastrophic DOC and DPF Failures
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Figure 12: Melted DPF
Item 1: Unit details (Do not block the damage with the tag).
Item 2: Clear image of the damage.
Description: Followed Aftertreatment Diagnostic Manual 0000003081 symptom 5 to step
2 , identified DPF was melted. Replaced DPF, followed to step 4 to verify system
operation found unit has a cracked injector tip that is the root cause of the DPF melting.
Completed all repairs and verified unit meets all operating specifications listed in the
engine diagnostic manual.
Post Repair Information
NOTE: This information does not need to be included in the warranty claim but must be performed to assure a proper
repair was conducted.
1. Unit should not have any obvious running issues (misfire, low power or knocking)
2. Unit should meet all of the performance specifications of its appropriate engine service manual
3. Unit should complete all tests successfully by meeting criteria outlined in the After Treatment Diagnostic Manual / Engine
Diagnostic Manual / V-8 Engine Diagnostic Reference Sheet (Linked Below)
OTHER RESOURCES
Master Service Information Site
2010 & HD-OBD I-6 & BB Engines Aftertreatment Symptom-Based Diagnostic and Inspection Manual (EPA 10)
N9 & N10 Engine with SCR (EPA 10) Diagnostic Manual
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IK1201258 Catastrophic DOC and DPF Failures
Page 11 of 11
N13 Engine with SCR (EPA 10) Diagnostic Manual
V-8 DPF & DOC Catastrophic Failure Performance Assessment Sheet
MaxxForce® 7 Engine Diagnostic Manual (EPA 10 with HD-OBD)
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Copyright © 2016 Navistar, Inc.
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TSB/Document ID: IK1201258
Replacement Service Bulletin Number:
MFR Communication Date: 2016-04-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
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