NHTSA ID Number: 10131005
Manufacturer Communication Number: REC16508
TSB/Document Date: 2018-04-02
Summary
The battery terminal mounted cube fuse connection that supplies power to the cab may possibly break, resulting in loss of power to the cab.
SERVICE PROCEDURE
16508
October, 2016
SUBJECT:
SAFETY RECALL
CUBE FUSE on certain ProStar® models built 11
June 2013 thru 19 May 2016 with feature 08WSP
(battery box mounted between the frame rails).
DEFECT DESCRIPTION
The battery terminal mounted cube fuse connection that supplies power to the
cab may possibly break, resulting in loss of power to the cab. A loss of power to
the cab may result in unexpected engine shutdown without warning and the
inability to restart the engine.
MODELS INVOLVED
This Safety Recall involves certain ProStar® models built 11 June 2013 thru 19
May 2016 with feature 08WSP (battery box mounted between the frame rails).
ELIGIBILITY
This procedure applies ONLY to vehicles marked in the International
® Service
PortalSM with Safety Recall 16508. Also complete any other open campaigns
listed on the Service Portal at this time.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
1
PARTS INFORMATION
Part Number
8900272R91
Part Description
Service Cable Kit; Cummins® Engines
Quantity
1
8900272R91 contains the following parts:
Part Description
BLOCK, FUSE, POWER PDM, 200/200 FUSES
CABLE, BATTERY, POS 000 GA SGR N/SEALED
BOLT, HEX FLG HD METRIC M8 X 30
NUT, HEX LOCK M8, CAD
NUT, HEX FLG LOCK, M10-1.5, SST
GUIDE,BRK HOSE & CABLE, SWIVEL
STRAP, CABLE LOCK
STRAP, CABLE LOCK, 20 IN. CABLE TIE
Part Number
8900273R91
Part Description
Service Cable Kit; Navistar® Engines
Quantity
1
1
2
2
2
1
2
4
Quantity
1
8900273R91 contains the following parts:
Part Description
BLOCK, FUSE, POWER PDM, 250/250 FUSES
SUPPORT, POWER BRACKET ASSEMBLY
CABLE, BATTERY, POS 0000 GA SGR N/SEALED
BOLT, HEX FLG HD METRIC M8 X 25
NUT, HEX LOCK M8, CAD
NUT, HEX METRIC PREV TORQ NUT, FLNG HD M12
STRAP, CABLE LOCK, 20 IN. CABLE TIE
NUT, HEX FLG LOCK, M10-1.5, SST
GUIDE,BRK HOSE & CABLE, SWIVEL
STRAP, CABLE LOCK
HEX FLG LOCK, M8-1.25, SST
Quantity
1
1
1
2
1
2
2
2
2
4
1
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
2
SERVICE PROCEDURE
WARNING! To prevent property damage, personal injury, and / or death,
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 both
directions.
WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.
WARNING! To prevent property damage, personal injury and / or death,
keep flames and sparks away from vehicle and DO NOT smoke while
servicing the vehicle’s batteries. Batteries expel explosive gases.
WARNING! To prevent property damage, personal injury and / or death,
remove the ground cable from the negative terminal of the battery box
before disconnecting any electrical components. Always connect the
ground cable last.
NOTE: The service procedures depicted in this document differ between
Cummins equipped vehicles and N13 equipped vehicles.
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission to Park or Neutral and set parking brakes.
3. Install wheel chocks.
4. Unlatch and open main battery box.
5. Disconnect ground cable from negative terminal of main vehicle battery.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
3
CUMMINS EQUIPPED VEHICLES
Figure 1. Battery Cables and Fuses
1. Cube fuse
2. Cab power cable
3. Main positive battery cable
6. Disconnect cab power cable (Figure 1, Item 2) from cube fuse.
7. Disconnect main positive battery cable (Figure 1, Item 3) from battery.
8. Remove cube fuse assembly (Figure 1, Item 1) from battery. Discard cube
fuse.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
4
Figure 2. Drill Locations
1.
2.
3.
4.
Raised center section
Operator-side edge
Drill location (3 inch / 75 mm)
Drill location (4 5/8 inch / 119 mm)
9. Using a marker, tape measure, ruler, or equivalent, mark drill locations:
Start from operator-side edge (Figure 2, Item 2) of raised
center section (Figure 2, Item 1) of battery box and measure
inward 3½ inches (87 mm). Starting at front edge of raised
center section of battery box, measure 3 inches (75 mm) to
establish drill location (Figure 2, Item 3). Mark this location.
Start from operator-side edge (Figure 2, Item 2) of raised
center section (Figure 2, Item 1) of battery box and measure
inward 7 1/8 inches (182 mm). Starting at front edge of
raised center section of battery box, measure 4 5/8 inches
(119 mm) to establish drill location (Figure 2, Item 4). Mark
this location.
10. Using a 1/8 inch bit, drill pilot holes into battery box at previously marked
drill locations.
11. Using a 7/16 inch bit, drill holes into battery box into both drill locations.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
5
Figure 3. Power Distribution Module (PDM)
1. PDM
2. M8 x 30 bolt (2)
3. M8 nut (2)
12. Align PDM assembly (Figure 3, Item 1) with drilled holes. Install two bolts
and two nuts (Figure 3, Items 2 & 3), and secure to box. Tighten
fasteners securely.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
6
Figure 4. Cab Feed and Frame Ground Cables
1. Cable tie wrap (4)
2. Saddle
13. Apply Grafo dielectric grease to cab feed cable terminal. Connect to PDM
and secure using M10-1.5 SST nut. Using torque wrench, tighten to 8.8
lb-in (30 N•m).
NOTE: Cab feed cable must be positioned inboard of frame ground cable.
14. Using cable tie wraps (Figure 4, Item 1), secure cab feed and frame
ground cable to saddle (Figure 4, Item 2) located on side of box.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
7
Figure 5. Jumper Cable and Cable Separator
1. Cable separator
2. Jumper cable
15. Apply Grafo dielectric grease to angled terminal end of cable jumper
cable (Figure 5, Item 2). Connect to PDM and secure with M10-1.5 SST
nut. Using torque wrench, tighten to 8.8 lb-in.
16. Route cable over top of negative interconnect. Install cable separator
(Figure 5, Item 1) and cable tie wrap to prevent cables from rubbing.
17. Apply Grafo dielectric grease to opposite end of jumper cable (Figure 5,
Item 2). Connect to positive terminal on battery post and install nut. Using
torque wrench, tighten to 142 - 177 lb-in (16 - 20 N•m).
18. Connect ground cable to negative terminal of main vehicle battery.
19. Proceed to Step 37.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
8
N13 EQUIPPED VEHICLES
Figure 6. Removing Cables and Fuses
1. Cube fuse
2. Cab power cable
3. Main positive battery cable
20. Remove cab power cable (Figure 6, Item 2) from cube fuse.
21. If trailer lift gate wiring is present in battery box, remove lift gate feed
from 2nd cube fuse.
22. Disconnect main positive battery cable (Figure 6, Item 3) from battery.
23. Remove cube fuse assembly (Figure 6, Item 1) from battery. Discard
cube fuse.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
9
Figure 7. Drill Locations
1.
2.
3.
4.
Raised center section
Drill location (12 3/8 inch / 314 mm)
Operator-side edge
Drill location (10 inch / 254 mm)
24. Using a marker, tape measure, ruler, or equivalent, mark drill locations:
Start from operator-side edge (Figure 7, Item 3) of raised
center section (Figure 7, Item 1) of battery box and measure
inward 1 5/8 inches (42 mm). Starting at front edge of raised
center section of battery box, measure 10 inches (253.6
mm) to establish drill location (Figure 2, Item 4). Mark this
location.
Start from operator-side edge (Figure 7, Item 3) of raised
center section (Figure 7, Item 1) of battery box and measure
inward 7½ inches (191 mm). Starting at front edge of raised
center section of battery box, measure 12 3/8 inches (313.6
mm) to establish drill location (Figure 2, Item 2). Mark this
location.
25. Using a 1/8 inch bit, drill pilot holes into battery box at previously marked
drill locations.
26. Using a 1/2 inch bit, drill holes into battery box into both drill locations.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
10
Figure 8. Attaching PDM to Support Bracket
1.
2.
3.
4.
M8 x 25 bolt (2)
PDM
Support bracket
M8 nut (2)
27. Using two bolts and two nuts (Figure 8, Items 1 & 4), attach PDM (Figure
8, Item 2) to support bracket (Figure 8, Item 3). Using torque wrench,
tighten to 204 in-lb (23 N•m).
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
11
Figure 9. PDM Subassembly Mounting
1. PDM subassembly
2. M12 nut (2)
28. Position PDM subassembly (Figure 9, Item 1) into previously drilled
holes. Use two nuts (Figure 9, Item 2) to secure to box. Using torque
wrench, tighten nuts to 45 - 55 lb-ft (61 - 75 N•m).
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
12
Figure 10. Cable Routing and Securing
1. Cable tie wrap (4)
2. Cable separator
3. Saddle
29. Route cab PDM feed and lift gate feed, if present, toward PDM. Ensure
that power feeds are not rubbing on negative battery post. Install cable
separator (Figure 10, Item 2) and cable tie wraps (Figure 10, Item 1) to
separate main feed from interconnect.
NOTE: Cab feed cable must be positioned inboard of clean power feed
cable.
30. Using cable tie wraps, secure cab PDM feed, clean power feed, and lift
gate feed if present, to saddle (Figure 10, Item 3) at box opening. Install
cable tie wrap (Figure 10, Item 1) to secure cables together.
31. Apply Grafo dielectric grease to cab main feed cable terminal. Connect to
PDM and secure using M10-1.5 SST nut. Using torque wrench, tighten
nut to 22 lb-ft (30 N•m).
32. If trailer lift gate wire is present, route to second fused output on PDM
and secure using M8-1.25 SST nut.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
13
Figure 11. Jumper Routing
1. Jumper cable
33. Apply Grafo dielectric grease to one end of jumper cable (Figure 11, Item
1) and connect to PDM. Secure with M10-1.5 SST nut. Using torque
wrench, tighten to 177 lb-in (20 N•m).
34. Apply Grafo dielectric grease to other end of jumper cable and connect to
positive battery terminal. Connect clean power cable and install hold
down nut. Using torque wrench, tighten nut to 142 - 177 lb-in (16 - 20
N•m).
35. Connect ground cable to negative terminal of main vehicle battery.
Using torque wrench, tighten to 142 - 177 lb-in (16 - 20 N•m).
36. Apply Grafo dielectric grease to all exposed metal terminals and to
unused posts on PDM.
37. Close and latch battery box cover.
38. Remove wheel chocks.
END OF SERVICE PROCEDURE
LABOR INFORMATION
Operation Number
A40-16508-1
Description
Replace Cube Fuse with PDM
Time
0.5 hr
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
14
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with this
campaign must be marked with a CTS-1075
Campaign Identification Label.
Complete the label and attach on a clean surface
next to the vehicle identification number (VIN) plate.
ADMINISTRATIVE / DEALER RESPONSIBILITIES
WARRANTY CLAIMS
Warranty claim expense is to be charged to Warranty. Claims are to be
submitted in the normal manner, making reference to Safety Recall 16508.
Section 7 of the Warranty Policy and Procedures Manual contains further
information related to the submission and processing of AFC / Recall claims.
As with all claim submissions, items acquired locally must be submitted in the
“Other Charges” tab. The cost of any bulk items (such as a bag of cable tie
straps, roll of wire, a barrel of oil, or a tube of silicone) should be prorated for the
cost of the individual pieces / amount used during each repair.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
15
UNITED STATES AND POSSESSIONS
The National Traffic and Motor Vehicle Safety Act, as amended, provides that
each vehicle that is subject to a vehicle recall campaign must be adequately
repaired within a reasonable time after the owner has tendered it for repair. A
failure to adequately repair within 60 days after a tender of a vehicle is prima
facie evidence of failure to repair within a reasonable time. If the condition is not
adequately repaired within 60 days, the owner may be entitled to replacement
with an identical or reasonable equivalent vehicle at no charge, or to a refund of
the purchase price less a reasonable allowance for depreciation.
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
CANADA
Dealers must correct all vehicles subject to this campaign at no charge to the
owner, regardless of mileage, age of vehicle, or ownership, from this time
forward.
Dealers should proceed immediately to make necessary correction to units in
inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your dealer location.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
16
Dealers must make every effort to promptly schedule an appointment with each
owner to repair his or her vehicle as soon as possible. However, consistent with
the customer notification, dealers are expected to complete the repairs on the
mutually agreed upon service date.
Dealers involved in the recall process will be furnished a listing of owner names
and addresses to enable them to follow up with owners and have the vehicles
corrected. Use of this listing must be limited to this campaign because the list
may contain information obtained from state motor vehicle registration records,
and the use of such motor vehicle registration data for purposes other than this
campaign is a violation of law in several states.
EXPORT
Export Distributors should proceed immediately to make necessary correction to
units in inventory. All inventory vehicles subject to this recall campaign must be
corrected prior to sale, transfer or delivery. If vehicles have been sold or
transferred and you are in receipt of Customer Notification Letters and
Authorization for Recall Service cards for those vehicles, the transfer location or
customer must be notified immediately from your distributor location.
Export Distributors are to submit warranty claims in the usual manner making
reference to this recall number.
Export Distributors are expected to provide full cooperation and follow-up with
respect to this important subject matter. If you have any questions or need
further assistance, please contact the Regional Service Manager at your regional
office.
NAVISTAR, INC.
VEHICLE RECALL 16508
© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
17
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TSB/Document ID: REC16508
Replacement Service Bulletin Number:
MFR Communication Date: 2016-10-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
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