IK1600166 Service Bulletin/Repair Instructions

IK1600166 - Water leaks through Cab Cowl pass-through connections
Page 1 of 3
Countries:
AUSTRALIA, CANADA, UNITED STATES,

MEXICO
Document ID: IK1600166
Availability:
ISIS, FleetISIS
Revision:
2
Major System :
CAB / SLEEPER / HOOD
Created:
11/16/2012
Current

Language:
English
Last

Modified:
11/16/2012
Author:
Patrick

Gotschall
Other Languages: NONE

Viewed:
149

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Title: Water leaks through Cab Cowl pass-through connections

Applies To: TerraStar, DuraStar, WorkStar, TranStar, ProStar, LoneStar

DESCRIPTION

This article describes the procedure for repairing the grommet pass-thorugh leaks.

REPAIR PROCEDURE

1. Remove each grommet from the body opening into which it was installed.

- The grommet simply has to be out of the body opening; it does not have to be completely removed from the vehicle.

2. Around the very edge of the body opening (on the engine compartment side of the cowl), have the technician spread a thin, but consistent, bead of black

body sealer.

- The sealer should look almost like a black o-ring if done correctly.

3. Reinstall the grommet, making absolutely certain that the sealer is “drawn” into the trough in the grommet as it is pushed into place.

4. Allow the sealer to dry for at least 2 hours; without disturbing the grommet in any way.

5. When the sealer is dry, have the technician systematically (one at a time) pull each air line or electrical wire that passes through a grommet, toward the

front of the truck, approximately 1 inch.

- The technician should be sure to mark the initial position of each line or wire with a marking pen.

6. With a specific line or wire pulled forward, have the technician wipe a “film” (of the same sealer used to seal the grommet) around the outer diameter of

the line/wire.

7. With the sealer film in place, have the technician carefully push the line/wire back in, to the marking point previously made.

See grommet image examples below:
*Exterior view of one of the Grommets in question*
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
12/3/2012
IK1600166 - Water leaks through Cab Cowl pass-through connections
Page 2 of 3
*Interior view of one of the Grommets in question*
*Evidence of the leaks on the floor of a new truck*
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
12/3/2012
IK1600166 - Water leaks through Cab Cowl pass-through connections
Page 3 of 3
*Evidence of the leaks on older trucks*
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Copyright © 2012 Navistar, Inc.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
12/3/2012

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