SERVICE PROCEDURE
14502
February 2014
SUBJECT:

SAFETY RECALL
STEERING GEAR MOUNTING BOLTS on certain
DuraStar® Models built 11 January 2014 through 23
January 2014 with feature codes 05PRG, 05PRR,
05PRU, 05PRV or 05PSM.

DEFECT DESCRIPTION
The mounting bolts that fasten the steering gear to the vehicle frame may not
be the correct bolt specified. These bolts could yield, resulting in either
looseness of steering or the potential for loss of steering if all four mounting
bolts were to yield. An unexpected loss of steering may result in a vehicle
crash, which may result in property damage, personal injury, or death.

MODELS INVOLVED
®
DuraStar models built 11 January 2014 through 23 January 2014 with feature
codes 05PRG, 05PRR, 05PRU, 05PRV or 05PSM.

PARTS INFORMATION
Part Number
31077R1
30756R1

Part Description
Bolt, Flanged Head M16 X100MM with
Phosphate and Oil Finish
Nut, Hex M16 PRVTRQ

Quantity
1-4
1-4

SERVICE PROCEDURE
WARNING! 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. FAILURE
TO DO SO MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY AND
/ OR DEATH.

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

1

WARNING! ALWAYS WEAR SAFE EYE PROTECTION WHEN PERFORMING
VEHICLE MAINTENANCE. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY AND / OR DEATH.

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. Determine steering gear feature code to determine which repair method is
necessary.
NOTE: For vehicles built with the following feature codes 05PSM –
Sheppard HD94, or 05PRU – TRW THP45 or 05PRV – TRW THP60 (Tables
1, 2 and 3), refer to Steps 5 - 32.

Sales Code - 05PSM, Sheppard HD94 Steering Gear
FL507166

FL140630

FL142508

FL182747

FL508360

FL035088

FL140686

FL144605

FL183057

FL509803

FL035090

FL140702

FL173850

FL183767

FL510116

FL070300

FL140703

FL181400

FL183778

FL510146

FL123163

FL140704

FL181425

FL507842

FL510203

FL125426

FL140717

FL181435

FL507891

FL511934

FL139940

FL140718

FL181588

FL507931

FL511935

FL140408

FL140824

FL182167

FL508290

FL512062

FL140422

FL140826

FL182551

FL508334

FL512064

FL140498

FL140834

FL182552

FL508335

FL140620

FL140995

FL182553

FL508336

Table 1
Sales Code - 05PRU, TRW THP45 Steering Gear
FL508149

FL182743

FL507809

FL507810

FL508971

Table 2

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

2

FL512233
FL027525
FL027526
FL141156
FL144547
FL509802
FL512163
FL512164
FL512165
FL512166
FL512167
FL512168
FL512169
FL512170
FL512171

Sales Code - 05PRV, TRW THP60 Steering Gear
FL512172
FL512187
FL512202
FL512173
FL512188
FL512203
FL512174
FL512189
FL512204
FL512175
FL512190
FL512205
FL512176
FL512191
FL512206
FL512177
FL512192
FL512207
FL512178
FL512193
FL512208
FL512179
FL512194
FL512209
FL512180
FL512195
FL512210
FL512181
FL512196
FL512211
FL512182
FL512197
FL512212
FL512183
FL512198
FL512213
FL512184
FL512199
FL512214
FL512185
FL512200
FL512215
FL512186
FL512201
FL512216

FL512217
FL512218
FL512219
FL512220
FL512221
FL512222
FL512223
FL512224
FL512225
FL512227
FL512228
FL512229
FL512230
FL512231
FL512232

Table 3
NOTE: For vehicles built with the following feature codes 05PRG – TRW
TAS40 or 05PRR – TRW TAS 66 (Tables 4 and 5), refer to Steps 33 - 40.

Sales Code - 05PRG, TRW TAS40 Steering Gear
FL181995
EL074177
EL123649
EL123650
EL142894

EL142895
EL143730
FL142670
FL181749
FL181766

FL181770
FL181969
FL181974
FL181975
FL181982

FL181986
FL181988
FL181994
FL182739
FL183692

FL507805

Table 4

Sales Code - 05PRR, TRW TAS66 Steering Gear
FL508368

Table 5

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

3

Figure 1. Steering Gear Bolt Mounting
Locations.
1.
2.
3.
4.

Bolt location 1
Bolt location 2
Bolt location 3
Bolt location 4

Bolt
Location

THP45

THP60

HD94

TAS40

TAS66

1

Replace

Bolt Ok

Replace

Inspect

Replace

2

Inspect

Bolt Ok

Replace

(No Bolt)

Replace

3

Inspect

Bolt Ok

Replace

Inspect

Replace

4

Bolt Ok

Replace

Bolt Ok

Replace

Replace

Table 6. Steering Gear Mounting Bolt
Reference Chart.
NOTE: Procedure Steps 5 - 32 represent vehicles equipped with Sheppard
HD94, TRW THP45, and TRW THP60 steering gears.
5. Unlatch and open hood.
6. Access steering gear mounting location.

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

4

7. Using steering gear reference (Figure 1, Items 1 - 4 and Table 6) and an
abrasive material, remove paint from thread end of bolt and inspect color:
•

If bolt(s) appears black after paint removal, no replacement is
necessary. Repaint inspected bolt.

•

If bolt(s) appears gray, proceed to next step.

8. Remove bumper.
9. Remove grille.
10. Remove hood.
11. Remove right side inner fender panel.
NOTE: Do not remove AC condenser lines.
12. Remove AC condenser fasteners and reposition.
13. Drain coolant.
14. Remove radiator package.
15. Support front of engine with overhead lift.
16. Remove engine crossmember side bracket bolts at frame rail and nuts at
mounting plate.
17. Lift engine enough to clear front engine mounts.
18. Slide crossmember assembly forward.
19. Remove suspect bolt(s) one at a time.
20. Install replacement steering gear bolt(s) and nut(s). Using a torque wrench,
torque bolts to 240 lb-ft (320 N·m).
21. Position crossmember and install with existing bolts. Using torque wrench,
torque crossmember as follows:
•

Torque lower engine crossmember to frame bolts to 65 - 80 lb-ft (88 108 N·m).

•

Torque upper engine crossmember to frame bolts to 80 - 100 lb-ft (108
- 135 N·m).

•

Torque upper engine crossmember to frame nuts to 81 lb-ft (110 N·m).

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

5

22. Lower engine and remove overhead lift.
23. Torque front engine mounts to 174 - 240 lb-ft (237 - 325 N·m).
24. Install radiator package.
25. Position and install AC condenser.
26. Fill cooling system.
27. Install right side fender panel.
28. Paint steering gear mounting bolts.
29. Install and latch hood.
30. Install grille.
31. Install bumper.
32. Remove wheel chocks.
NOTE: Procedure Steps 33 - 40 represent vehicles equipped with TRW
TAS40 and TRW TAS66 steering gears.
33. Unlatch and open hood.
34. Access steering gear mounting location.
35. Using steering gear reference (Figure 1, Items 1 - 4 and Table 6) and an
abrasive material, remove paint from bolt and inspect color:
•

If bolt(s) appears black after paint removal, no replacement is
necessary. Repaint inspected bolt.

•

If bolt(s) appears gray, proceed to next step.

36. Remove the suspect bolt(s) one at a time.
37. Install replacement steering gear bolts. Using a torque wrench, torque bolts
to 240 lb-ft (320 N·m).
38. Paint replacement steering gear mounting bolts.
39. Close and latch hood.
40. Remove wheel chocks.

VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

6

END OF SERVICE PROCEDURE

LABOR INFORMATION
Operation Number

A40-14502-1
A40-14502-2
A40-14502-3

Description

Inspection of Steering Gear Bolt Color.
Inspection and Replacement of Bolts for TRW
TAS40 and TRW TAS66 Gears.
Inspection and Replacement of Bolts for
Sheppard HD94, TRW THP45 and TRW THP
60 Gears.

Time

0.3 hr
0.5 hr
3.5 hrs

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 14502.
It is important that the coding be completed properly to assist in processing the
warranty claim. Complete instructions will be found in the Warranty Policy
Manual, Section 7.1.8.
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 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

7

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
VEHICLE RECALL 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

8

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.
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 14502
© 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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