NAYVISTAR

AUTHORIZED FIELD CHANGE - 23901
17 August 2023

SUBJECT: Sealing roof joints during Safety Recall 23501 or 23502 is performed if
required.

MODELS INVOLVED:
IC Bus® RE, CE, and Electric CE Series buses

DEFECT DESCRIPTION:

Certain IC Bus® applications may have roof water leaks resulting from incorrect
assembly described in Roof Joint Recalls 23501 and 23502. This document will guide
the user through resealing the source of the roof water leaks.

ELIGIBILITY:

This procedure applies ONLY to vehicles marked in the International® Service Portal
with AFC 23901. Also complete any other open campaigns listed on the Service Portal
at this time.

TOOLS REQUIRED:
No special tools required

PARTS REQUIRED:

NOTE: A tube of sealant may seal up to two rows of rivets and / or screws. Up to
four or five tubes may be required depending on the number of joints repaired.

Number Description Quantity
Dicor 501LSW | Sealant, White, 11 oz. Tube (Purchase Online) As needed
810000KK Sealant, Yellow, 11 oz. Tube (Direct Ship) As needed

Table 1 Parts Information

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SERVICE PROCEDURE

GOVERNMENT REGULATION: Engine fluid (oil, fuel, and coolant) may be a
hazard to human health and the environment. Handle all fluid and other
contaminated materials (such as filters and rags) in accordance with applicable
regulations. Recycle or dispose of engine fluids, filters, and other contaminated
materials according to applicable regulations.

WARNING! To prevent personal injury and / or death, or damage to property, 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.

WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.

WARNING! To prevent personal injury and / or death, or damage to property, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.

WARNING! To prevent personal injury and / or death, or damage to property, work
on a level scaffold of appropriate size and / or wear a safety harness in good
working condition. IC Bus, LLC recommends the use of a fall protection system
and / or scaffolding to perform this service procedure. Consult your OSHA
representative for guidance.

CAUTION! To prevent damage to property, when working on the vehicle roof and /
or working directly over a roof bow, ALWAYS ENSURE that clean / non-scuffing
shoes or boots are worn to prevent scratches or unnecessary marking to the roof
surface. AVOID walking on the roof in an upright position. Sitting or lying on the
roof helps to ensure the technician’s body weight is evenly distributed over a
large surface to minimize denting.

CAUTION! To prevent damage to property, NEVER use cloth shop rags / towels to
clean surfaces. Even if clean, cloth shop rags / towels may contain an oily residue
that may negatively interfere with the sealant adhering to the surface of the bus.

IMPORTANT: Portions of this repair procedure must be performed on the roof of
the bus. Please refer to the Warning depicted in this document and consult your
facility’s OSHA guidelines related to safety requirements before performing this
procedure.

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NOTE: This AFC should be performed while performing Safety Recall 23501 or
23502 if joints are repaired under such safety recall. Refer to Safety Recall 23501
or 23502 that pertains to this vehicle for detailed instructions.

1.

2.

3.

4.

Park vehicle on a flat surface.
Shift transmission to Park or Neutral and set parking brake.
Turn vehicle ignition to Key OFF position.

Install wheel chocks.

NOTE: Refer to Figure 5 in Safety Recall 23501 or 23502 for screws with sealant.

NOTE: The first revisions of Safety Recall 23501 and 23502, which included
sealing of the screws, were released in May 2023.

5.

Starting at rearmost top panel of bus, determine if panel(s) were repaired under
Safety Recall 23501 or 23502.

a. If panel(s) had repairs completed and roof bow screws sealed, applying
sealant to rivets is required. Perform Steps 6 through 10 and then proceed to
Step 16.

b. If panel(s) had repairs completed in April or May 2023 and before Revision 1
of Safety Recall 23501 and 23502 released in May 2023, applying sealant to
rivets and screws is required. Perform Steps 11 through 17.

c. If panel(s) had no repairs needed, applying sealant to rivets and screws is not
required. Proceed to Step 17.

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&

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0000478736

Figure 1. Roof Joint Leak Repair Rivet Location

1. Rear row of screws
2. Forward row of rivets

CAUTION! To prevent damage to property, when working on the vehicle roof and /
or working directly over a roof bow, ALWAYS ENSURE that clean / non-scuffing
shoes or boots are worn to prevent scratches or unnecessary marking to the roof
surface. AVOID walking on the roof in an upright position. Sitting or lying on the
roof helps to ensure the technician’s body weight is evenly distributed over a
large surface to minimize denting.

6. Starting with rearmost top panel that required screws (Figure 1, Item 1), locate
forward row of rivets (Figure 1, Item 2).

© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 4

CAUTION! To prevent damage to property, NEVER use cloth shop rags / towels to
clean surfaces. Even if clean, cloth shop rags / towels may contain an oily residue
that may negatively interfere with the sealant adhering to the surface of the bus.

7. Clean surface with non-oil-based cleaner and wipe dry.

0000478463,

Figure 2. Add Sealant to Rivets

1. Sealant
2. Rivet head

NOTE: In line with the forward row of rivets of the repaired joint, up to
approximately 35 rivets will require sealant.

8. Starting at 20 in (508 mm) up from drip rail, apply appropriate color sealant (Figure
2, Item 1) to perimeter of rivet head (Figure 2, Item 2).

9. Repeat Steps 7 and 8 for each rivet in forward row of rivets of repaired joint.

10. Repeat Steps 7 through 9 for each repaired joint.

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0000478735

Figure 3. Roof Joint Leak Repair Screw Location

1. Rear row of screws
2. Forward row of rivets
3. Existing rivet

CAUTION! To prevent damage to property, when working on the vehicle roof and /
or working directly over a roof bow, ALWAYS ENSURE that clean / non-scuffing
shoes or boots are worn to prevent scratches or unnecessary marking to the roof
surface. AVOID walking on the roof in an upright position. Sitting or lying on the
roof helps to ensure the technician’s body weight is evenly distributed over a
large surface to minimize denting.

11. Starting with rearmost top panel that required screws, locate forward row of rivets
(Figure 3, Item 2) and rear row of screws (Figure 3, Item 1).

© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 6

CAUTION! To prevent damage to property, NEVER use cloth shop rags / towels to
clean surfaces. Even if clean, cloth shop rags / towels may contain an oily residue
that may negatively interfere with the sealant adhering to the surface of the bus.

12. Clean surface with non-oil-based cleaner and wipe dry.

0000478024

Figure 4. Add Sealant to Screws
1. Sealant

NOTE: In line with the rearmost row of rivets of the repaired joint, up to
approximately 19 screws and 35 rivets will require sealant.

13. Starting at 20 in (608 mm) up from drip rail, apply appropriate color sealant (Figure
4, Item 1) to perimeter of rivet and screw head.

14. Repeat Steps 12 and 13 for each rivet in forward row of rivets and each screw in
rear row of rivets of repaired joint.

15. Repeat Steps 12 through 14 for each repaired joint.

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16. Once all appropriate rivets and / or screws have been sealed, carefully remove
scaffolding and / or safety harness.

17. Remove wheel chocks.

LABOR INFORMATION

Operation number must appear on all claims.

Operation Number Description Time
A40-23901-1 Repair One Joint 0.3 hrs
A40-23901-2 Repair Each Additional Joint; As Needed 0.2 hrs

Table 2 Labor Information

WARRANTY CLAIMS

Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner, making reference to Field Service Campaign 23901.

Section 7 of the Warranty Policy and Procedures Manual contains further information
related to the submission and processing of AFC / Recall claims.

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,
barrel of oil, or tube of silicone) should be prorated for the cost of the individual pieces /
amount used during each repair.

To make sure this important improvement is made in a timely manner, all claims for
23901 activity must be submitted by 17 August 2023 or within the normal warranty
period for the component, if after 17 August 2024.

© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 8