NHTSA ID Number: 10153655
Manufacturer Communication Number: IK0700100
TSB/Document Date: 2019-02-25
Summary
DPF Cracking
IK0700100 - Maxx7 2010 DPF Cracking
Page 1 of 5
Countries:
CANADA, UNITED STATES,
MEXICO
Document ID: IK0700100
Availability:
ISIS, Bus ISIS, FleetISIS, IsSIR
Revision:
5
Major System:
Created:
8/7/2017
English
Last
Modified:
12/20/2018
Author:
Jon Pierce
Current
Language:
Other Languages: NONE
Viewed:
2614
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Title : Maxx7 2010 DPF Cracking
Applies To : ESN below 5340000 or if the current calibration is one of the following PRS29XR5,
PRS19XR5, PRS29XP5, PRS19XP5, PRS29XH5, PRS29XRA, PRS19XRA.
CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
12/20/2018 - updated matrix and switched DOC part numbers between 4X2 and 4X4 - visually confirmed new matrix is correct
11/14/2017 - additional correction to matrix in the 4X4 section
11/4/2017 - corrected parts matrix
08/28/2017 - corrected ESN range
08/07/2017 - Initial Article Release
DESCRIPTION
This document will guide the user through identifying and replacing a cracked DPF with an updated DOC and preDOC
combination.
SYMPTOM(s)
Black smoke on snap acceleration tests, check engine light on, low power and unable to complete a proper regen.
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light
Description
SPN 3251 FMI 21 FCAP
DPFDP excessivly low
SPN 3936 FMI 0 FCAP
DPF Soot Load – Severe De-rate (regen
disabled)
SPN 5319 FMI 31 FCAP
DPF Incomplete Regeneration
Customer Observations or Concerns:
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IK0700100 - Maxx7 2010 DPF Cracking
Page 2 of 5
Check engine light on, black smoke under acceleration. Customer may also experience poor engine performance.
SPECIAL TOOL(s) / SOFTWARE
Tool Description
Tool Number
Comments
Electronic Service
Tool
J-45067
Ensure your EZ tech has
the latest updates available.
SERVICE PARTS INFORMATION
To determine the proper parts needed for this repair you will need to refer to the parts catalog and obtain
the production turbo downpipe part number and production DPF/DOC assembly number. Once that information is
obtained refer to the matrix linked below for the new turbo down pipe and doc part number.
There may be a long lead time for some of these DOC and downpipe assemblies. Do not down the truck while waiting
for new parts for an extended period of time. If the unit needs to be put back in service install orginal parts to get the
unit back online. Then schedule the unit back in for installation of the new parts.
A service calibration is required for this repair to be completed. A tech service case file must be created to get the
engine updates added to the engine you are working on.
Parts Matrix
Additional parts you may need:
Quantities not given as these parts are on an as needed bassis.
Part Number
Description
Location Used
3844630C1
Clamp, Exhaust pipe 3.5" V-Band
Turbo down pipe
2593986C1
Gasket, flange offset 3 hole
back of DPF
2593998C1
Gasket, Flange 3 bolt
Front of DPF
2604079C1
M10 X 50 X 1.5 6H Bolt
Mounting Hardware
2593991C1
Nut, Flange hexagon M10 X 1.5
Mounting Hardware
DIAGNOSTIC STEP(s)
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IK0700100 - Maxx7 2010 DPF Cracking
Step Action
DIAGNOSTIC:
Page 3 of 5
Decision
Yes. Goto Step 2
Perform snap acceleration test:
Black smoke present durring test?
1
No. End diagnostics for this symptom
Step Action
2
Decision
DIAGNOSTIC:
1.Concern found: Repair any defects
found durring operational check.
Perform Preliminary Vehicle Operational Checkout Procedure
Diagnostic Manual
2. No Concern found: Goto next step.
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IK0700100 - Maxx7 2010 DPF Cracking
Step Action
DIAGNOSTIC:
Perform Base Engine Analysis Module per diagnostic manual.
Diagnostic Manual
Page 4 of 5
Decision
1.If defects are found durring testing,
repair these defects first.
2. Verify no other defects found.
3
3. Proceed to R/R procedure.
REPAIR STEP(s)
Always refer to the service portal for complete assembly and removal processes.
REMOVAL PROCEDURE:
1. Install wheel chocks and disconnect and isolate the negative battery cable
2. Remove the DPF and DOC assemblies Component Manual
3. Remove the turbo downpipe.
4. With the exhaust system removed inspect the hangers and isolatoers, replace as needed.
INSTALLATION PROCEDURE:
Install components loosely to ensure proper fittment. Than torque to specification.
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IK0700100 - Maxx7 2010 DPF Cracking
Page 5 of 5
1. Install turbo down pipe and v-clamp.
2. Install DOC and DPF assembly.
3. Torque all components to specification.
4. Reconnect batteries.
5. Install ECM strategy after tech services says it's ready.
This service calibration does not work well with NavKal. Using NETS is the best option to ensure a proper software
install.
6. Always choose the change parameters option when receiving the file. Nets Programming and Troubleshooting Guide .
WARRANTY INFORMATION
Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.
Standard Repair Time(s):
Refer to the SRT Manual for Repair Times
OTHER RESOURCES
Master Service Information Site
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Copyright © 2019 Navistar, Inc.
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TSB/Document ID: IK0700100
Replacement Service Bulletin Number:
MFR Communication Date: 2018-12-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
MFR Component System:
MFR Component Subsystem:
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