IK1600207 - Wind noise at upper side of cab door due to door out of alignment

Countries:

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AUSTRALIA, BAHAMAS, BOLIVIA, BELIZE,
CANADA, CHILE, TAIWAN, COLOMBIA,
COSTA RICA, DOMINICAN REPUBLIC,
ECUADOR, EL SALVADOR, TRINIDAD AND
Document
TOBAGO, UNITED STATES, URUGUAY,
IK1600207
ID:
VENEZUELA, MEXICO, ARUBA, NICARAGUA,
PERU, PUERTO RICO, Curaçao, GUAM,
GUATEMALA, GUYANA, HAITI, HONDURAS,
JAMAICA, KOREA, SOUTH KOREA, PANAMA

Availability: ISIS, FleetISIS, IsSIR

Revision: 7

Major
System:

CAB / SLEEPER / HOOD

Created:

Current
Language:

English

Last
11/12/2019
Modified:

Other
NONE
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Author:

6/5/2014

Steven
Bautz

1639
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Title : Wind noise at upper side of cab door due to door out of alignment
Applies To : LT, MV, HV, RH, LoneStar, ProStar, TranStar, WorkStar, DuraStar, TerraStar. (Does not
apply to CV, PayStar, or HX)

CHANGE LOG
Dealers: Please refer to the change log text box below for recent changes to this article:
11/12/2019 - Updated "Applies To" section by adding the new International Series to this article.
03/11/2019 - Added information for use of alternate shim stock in place of the service kit based on user feedback.
04/19/2018 - Author updated for feedback purposes.
07/20/2017 - Author updated for feedback purposes.
06/06/2016 - Author addressed feedback.
07/14/2014 - Initial release. Supersedes IK1600022, IK1600035, IK1600090, TSI 05-16-04, and SFN 0426.
08/11/2014 - Edited step 2

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DESCRIPTION
There are instances when the cab side entry door does not have proper contact with the door seals along the top of the door
causing wind noise and/or flutter sounds. In extreme cases and in inclement weather, there could be water intrusion as well.
Many design improvements were made between 2004 and 2009 that drastically improved quality in this area, however there are
still isolated occurrences when this issue still persists.

SYMPTOM(s)
Customer Complaint(s):
• Wind noise through cab entry door
• Flutter sounds near top of cab entry door
• Water intrusion through top seal of cab entry door

SERVICE PART(s) INFORMATION
Kit Description

Part Number

Quantity Required Ordering Instructions

Shim Kit*

2587820C91

1 kit per door

Order from Navistar
Service Parts
Order Locally

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IK1600207 - Wind noise at upper side of cab door due to door out of alignment

Commercial Body
Shim Kit

Various based on
manufacturer

Page 2 of 5

1 kit may cover
many doors

* The International shim kit contains an instruction sheet, one 1.5mm shim and three 0.5mm shims. This kit has the
recommended parts; only use alternates if the Navistar kit not available through PDC at the time of service.
Note: If the PDC does not have inventory of the International Shim Kit listed above. Try one of these 2 options:
1. Purchase or use a body shim kit that contains shims of similar thickness. (1/64" Thick and 1/16" Thick). Use shims one at
each bolt location per hinge in place or one custom shim per hinge.
Example of a Body Shim Kit with Assorted Shims:

2. If your shop has the capability; fabricate the required shims using shim stock with the following dimensions per the
thicknesses listed above.

REPAIR STEP(s)

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IK1600207 - Wind noise at upper side of cab door due to door out of alignment

Page 3 of 5

1. Inspect the primary (Figure 1, Item 3) and secondary (Figure 1, Item 1) door seals. Ensure they are seated down
completely. If there is any visible damage or waves, adjust or replace as necessary.
2. Inspect the door to ensure proper positioning and flushness within the door frame. Refer to the specific cab service
manual under "Adjustments: Cab Door" (general information), "Adjustments: Door Hinge" (affects door positioning), and
"Adjustments: Striker Pin" (affects door flushness).
3. After replacing or adjusting any of the parts in steps 1 or 2, remove the primary door seal (Figure 1, Item 3).
4. While closing the door, place a dollar bill or similar size/shape piece of paper between the secondary door seal (Figure 1,
Item 1) and the door (Not Shown) at the base of the A-pillar where the secondary door seal starts/terminates just above
the upper door hinge (Figure 2, Item 1).
5. Slide the dollar bill up and along the door all the way back to the upper rear corner of the door.
6. If the dollar bill does not slide freely, there is proper contact between the door and seal and no shimming is required.
Reinstall the primary door seal (Figure 1, Item 3), ensuring that it is completely seated all the way around the door
perimeter. The job is complete.
7. If the dollar bill slides freely, there is not a proper amount of contact between the door and the door seal. Continue below.
8. Loosen the lower A-pillar door hinge bolts (Figure 2, Item 3).
9. Insert the thickest shim (1.5mm) between the cab hinge pillar (Figure 2, Item 4) and the lower door hinge (Figure 2, Item
2). Position the shim with the long "ear" forward so the shim is completely covered by the hinge.
10. Re-tighten the lower hinge bolts (Figure 2, Item 3) to 19.6 - 24.0 N-m (14.5 - 17.7 Lbf-ft).
11. Repeat steps 4-10 using the 0.5mm shim until the issue is resolved. Do not use more than one shim kit on each door
(total shift of 3.0mm).

Figure 1: Door Seals
Item 1: Secondary Door Seal
Item 2: Weather Seal Flange
Item 3: Primary Door Seal

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IK1600207 - Wind noise at upper side of cab door due to door out of alignment

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Figure 2: Door Hinges
Item 1: Upper Door Hinge
Item 2: Lower Door Hinge
Item 3: Hinge Mounting Bolts
Item 4: Cab Hinge Pillar

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 16012
Noun:

130

Standard Repair Time(s):

Description

SRT Link

Hours

Door Adjustment
Procedure

A16-T1 (SRT to publish with August 2014
release)

0.7

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