IK1600247 Service Bulletin/Repair Instructions

IK1600247 - Hood Gap and Alignment Tolerances
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IK1600247

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Availability: ISIS, FleetISIS, NotSIR
Revision: 2
Major

System:
CAB / SLEEPER / HOOD
Created:
English
Last

1/25/2019

Modified:
Current

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5/22/2018
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Title : Hood Gap and Alignment Tolerances

Applies To : LT/ProStar/8000, Eagle/9000, HV/WorkStar/7000, HX/PayStar, MV/DuraStar/4000
CHANGE LOG

Please refer to the change log text box below for recent changes to this article:

01/25/2019 ­ Added MV/DuraStar/4000.

06/22/2018 ­ French and Spanish translation added

06/13/2018 - Initial Article Release



DESCRIPTION

This document will guide the user through what the allowable gaps should be between the hood and the surrounding body parts once the hood has

been properly installed as recieved from the factory or after being serviced in the field. The gaps are an important part of the overall vehicle

appearance and should be maintained as outlined in this article.

Reference other iKnow articles that may be helpful when verifying the hood gaps are IK1600071 for 4000 Series, IK1600108 for LoneStar, and

IK1600189 for 9000 Series.
SYMPTOM(s)

1. Hood Gaps are too big or too tight.

2. The gap is not consistant from left to right or from top to bottom.

3. Body panels on either side of the gap are not flush.

4. A misaligned hood may cause unwanted rubbing and/or wear between body parts that will lead to damage to top coat finish.

5. A misaligned hood or improper gap may cause excessive noise/clapping during vehicle operation under certain conditions.
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s)

Not Applicable
Customer Observations or Concerns

Hood gap & alignment to body panels are important for overall appearance and proper performance of the vehicle.
SPECIAL TOOL(s) / SOFTWARE
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 2/1/2019
IK1600247 - Hood Gap and Alignment Tolerances
Tool Description
Tool Number
Tape Measure
obtain locally
Wood/Plastic Block

Cotton or Latex Gloves
Page 2 of 10
Comments
Instructions
obtain locally
Used to extend edges when

measuring gap.
As shown in photos
obtain locally
Use to ptotect top coat finish
SERVICE PARTS INFORMATION

Not Applicable
DIAGNOSTIC STEP(s)

Not Applicable
HOOD GAP INSPECTION STEP(s)
Wear soft gloves and take care not to scratch or damage top coat finish.
LT/ProStar/8000, MV/DuraStar/4000 - Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Comments
A
17mm - 29mm
See Figure 1, photos 1-2
B
17mm - 29mm
See Figure 1, photos 1-3
A to B Paralleism
4mm Max
Difference between A & B
Lt Side Gap vs Rt Side Gap
6mm Max
Difference between left & right sides
Measuring the hood to door gap. (Right side is shown, Left side is the same but opposite)

Measure at both Point A and Point B as shown in Figure1. Refer to Photos 2 & 3 in Figure 1 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
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Figure 1: LT/ProStar/8000 and MV/DuraStar/4000

Photo 1: Overall view of right side gap showing Point A & Point B.

Photo 2: Measurement at Point A.

Photo 3: Measurement at Point B.
LT & MV Gaps Only

Cab to Hood Flushness
Requirement

0 - 5mm
Comments

See Photo 1 in Figure 2 below
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IK1600247 - Hood Gap and Alignment Tolerances
Page 4 of 10
Figure 2: LT & MV Gaps Only - Flushness & Charater Line

Photo 1: Measuring Hood Flushness to Cab Door using plastic block & Tape Measure

Photo 2: Example of a misaligned hood. (This photo depicts an unacceptable condition.)
Eagle/9000 Series with Dual DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Comments
Horizontal Gap
32mm - 42mm
Reference Figure 3 below
Vertical Gap
14mm - 24mm
Reference Figure 3 below
Measuring the hood to cab gaps. (Right side is shown, Left side is the same but opposite)

Measure both Horizonal & Verticle gaps as shown in Figure 3. Refer to Photos 2-5 in Figure 3 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
Page 5 of 10
Figure 3: Eagle & 9000 Series Hood Gap & Alignment

Photo 1: Overall view of right side gap. Left side is the same but opposite.

Photo 2-3: Measurement of Horizontal Gap.

Photo 4-5: Measurement of Vertical Gap.

Drawing 1: Reference Only
9000 Series without Dual DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Vertical Gap at Hood Seam 15.08mm - 20.32mm
Comments

Reference Figure 4, photo 3
Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)

Measure both Horizonal & Verticle gaps as shown in Figure 4. Refer to Photos 2-5 in Figure 4 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
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Figure 4: 9000 Series Hood Gap & Alignment

Photo 1: Overall view of left side hood to cab gap. Right side is the same but opposite.

Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.
HV/WorkStar/7000 Series- Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Comments
A
17mm - 29mm
See Figure 5, photos 1 & 2
B
17mm - 29mm
See Figure 5, photos 1 & 2
A to B Paralleism
4mm Max
Difference between A & B (both sides)
Lt Side Gap vs Rt Side Gap
6mm Max
Difference between left & right side of truck
Measuring the hood to door gap. (Right side is shown, Left side is the same but opposite)

Measure at both Point A and Point B as shown in Figure5. Refer to Photo 2 in Figure 5 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
Page 7 of 10
Figure 5: HV/WorkStar/7000 Series Hood & Gap Alignment

Photo 1: Overall view of right side gap showing Point A & Point B.

Photo 2: Measurement at Point A & Point B.

Photo 3 & 4: Measurement of Characteristic Line.
Gaps
Requirement
Comments
Characteristic Line
0 +/- 5mm
See Figure 5, photo 3. Check both sides of truck
Cab to Hood Flushness
0 - 5mm Max
See FIgure 5, photo 4. Check both sides of truck
HX 515 without DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Comments
A
16mm - 26mm
See Figure 6, photos 1 & 2
B
17mm - 25mm
See Figure 6, photos 1 & 3
A to B Paralleism
5mm Max
Difference between A & B (both sides)
Flushness Cab to Hood
4mm Max
See Figure 6, Photo 4
4mm Max
Difference between the gaps from the left & right

side of truck.
Left Side Gap vs Rt Side Gap
Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)

Measure both Horizonal & Verticle gaps as shown in Figure 6. Refer to Photos 1-3 in Figure 6 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
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Figure 6: HX 515 Hood Gap & Alignment

Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.

Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.

Photo 4: Gap flushness.
HX 620 with DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment Tolerances:

Gap Location
Requirement
Comments
A
18mm - 30mm
See Figure 7, photos 1 & 2
B
22mm - 34mm
See Figure 7, photos 1 & 3
C
17mm-29mm
See Figure 7, photo 4
A to B Paralleism
5mm Max
Lt Side Gap vs Rt

Side Gap
4mm Max
Difference between A & B

(both sides)

Difference between the

gaps from the left & right

side of truck.
Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)

Measure both Horizonal & Verticle gaps as shown in Figure 7. Refer to Photos 1-4 in Figure 7 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
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Figure 7: HX 620 with DEACs Hood Gap & Alignment

Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.

Photo 2-3: Measurement of hood to cab verticle gap at hood seam location.

Photo 4: Gap flushness.
HX 615 & 620 with Extention without DEACs (Air Filters) - Review and Inspection of Hood Gap & Alignment

Tolerances:

Gap Location
Requirement
Comments
A
18mm - 30mm
See Figure 8, photos 1 & 2
B
21mm - 33mm
See Figure 8, photos 1 & 3
Vertical Gap Paralleism
5mm Max
Difference between A & B (both sides)
Lt Side Gap vs Rt Side Gap
4mm Max
Difference between the gaps from the

left & right side of truck.
Measuring the hood to cab gap. (Left side is shown, Right side is the same but opposite)

Measure both Horizonal & Verticle gaps as shown in Figure 8. Refer to Photos 1-3 in Figure 8 for measurment technique.
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IK1600247 - Hood Gap and Alignment Tolerances
Page 10 of 10
Figure 8: HX 615 & 620 with Extension without DEACs Hood Gap & Alignment

Photo 1: Overall view of right side hood to cab gap. Left side is the same but opposite.

Photo 2-3: Measurement of hood to cab verticle gap & Fender seam location.
REMOVAL/ INSTALLATION PROCEDURE

Refer to appropriate service manual
WARRANTY INFORMATION

Warranty Claim Coding:

Refer to the Warranty Coding Manual for Group and Noun Codes.
STANDARD REPAIR TIME

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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