IK1600207 ­ Wind noise at upper side door

Page 1 of 3

Countries:

AUSTRALIA, BAHAMAS, BOLIVIA, BELIZE,
CANADA, CHILE, TAIWAN, COLOMBIA,
COSTA RICA, DOMINICAN REPUBLIC,
ECUADOR, EL SALVADOR, TRINIDAD AND
Document
TOBAGO, UNITED STATES, URUGUAY,
IK1600207
ID:
VENEZUELA, MEXICO, ARUBA, NICARAGUA,
PERU, PUERTO RICO, Curaçao, GUAM,
GUATEMALA, GUYANA, HAITI, HONDURAS,
JAMAICA, KOREA, SOUTH KOREA, PANAMA

Availability: ISIS, FleetISIS

Revision: 2

Major
System:

CAB / SLEEPER / HOOD

Created:

English

Last
6/6/2016
Modified:

Current
Language:

Other
NONE
Languages:
Viewed:

Author:

6/5/2014

David
Smith

859
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative
Link

Bookmark

Add to Favorites

Print

Edit Document

Provide
Feedback

View My
Bookmarks

Helpful

Not Helpful

13

2

Title : Wind noise at upper side door
Applies To : All steel cabs: ProStar, LoneStar, TranStar, WorkStar, DuraStar, TerraStar

CHANGE LOG
Dealers: Please refer to the change log text box below for recent changes to this article:
06/06/2016 - Author addressed feedback
7/14/2014 ­ Initial release. Supersedes IK1600022, IK1600035, IK1600090, TSI 05­16­04, and SFN 0426.
8/11/2014 - Edited step 2




DESCRIPTION
There are instances when the cab side entry door does not have proper contact with the door seals along the top of the door
causing wind noise and/or flutter. In extreme cases and in inclement weather, there could be water intrusion as well. Many
design improvements were made between 2004 and 2009 that drastically improved quality in this area, however there are still
isolated occurrences when this issue still persists.
SYMPTOM(s)
Customer Complaint(s):
­ Wind noise
- Flutter
- Water intrusion

SERVICE PART(s) INFORMATION

Kit Description

Part Number

Quantity Required

Ordering Instructions

Shim Kit*

2587820C91

1 per door

Order from Navistar

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2016

IK1600207 ­ Wind noise at upper side door

Page 2 of 3

* The shim kit contains an instruction sheet, one 1.5mm shim and three 0.5mm shims.
REPAIR STEP(s)
1. Inspect the primary (Figure 1, Item 3) and secondary (Figure 1, Item 1) door seals. Ensure they are seated down
completely. If there is any visible damage or waves, adjust or replace as necessary.
2. Inspect the door to ensure proper positioning and flushness within the door frame. Refer to the specific cab service
manual under "Adjustments: Cab Door" (general information), "Adjustments: Door Hinge" (affects door positioning), and
"Adjustments: Striker Pin" (affects door flushness).
3. After replacing or adjusting any of the parts in steps 1 or 2, remove the primary door seal (Figure 1, Item 3).
4. While closing the door, place a dollar bill or similar size/shape piece of paper between the secondary door seal (Figure 1,
Item 1) and the door (Not Shown) at the base of the A-pillar where the secondary door seal starts/terminates just above
the upper door hinge (Figure 2, Item 1).
5. Slide the dollar bill up and along the door all the way back to the upper rear corner of the door.
6. If the dollar bill does not slide freely, there is proper contact between the door and seal and no shimming is required.
Reinstall the primary door seal (Figure 1, Item 3), ensuring that it is completely seated all the way around the door
perimeter. The job is complete.
7. If the dollar bill slides freely, there is not a proper amount of contact between the door and the door seal. Continue below.
8. Loosen the lower A-pillar door hinge bolts (Figure 2, Item 3).
9. Insert the thickest shim (1.5mm) between the cab hinge pillar (Figure 2, Item 4) and the lower door hinge (Figure 2, Item
2). Position the shim with the long "ear" forward so the shim is completely covered by the hinge.
10. Retighten the lower hinge bolts (Figure 2, Item 3) to 19.6 - 24.0 N-m (14.5 - 17.7 Lbf-ft).
11. Repeat steps 4-10 using the 0.5mm shim until the issue is resolved. Do not use more than one shim kit on each door
(total shift of 3.0mm).

Figure 1: Door Seals
Item 1: Secondary Door Seal
Item 2: Weather Seal Flange
Item 3: Primary Door Seal

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2016

IK1600207 ­ Wind noise at upper side door

Page 3 of 3

Figure 2: Door Hinges
Item 1: Upper Door Hinge
Item 2: Lower Door Hinge
Item 3: Hinge Mounting Bolts
Item 4: Cab Hinge Pillar
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 16012
Noun:

130

Standard Repair Time(s):
Step Description

SRT Link

Hours

Door Adjustment A16-T1 (SRT to publish with August 2014
0.7
Procedure
release)

Hide Details

Feedback Information
Viewed:

858

Helpful:

13

Not Helpful: 2
No Feedback Found

Copyright © 2016 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2016