CANADA, UNITED STATES Document ID: 1K1201463

* lity ISIS, IsSIR Revision: 19
Major System: ENGINE Created: 10/14/2021
Current Language: English Last Modified: 6/28/2024

Knowledge Base Other Languages: NONE Author: Marcelo Sahagun
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Title: A26 Connecting Rod Replacement Process

Applies To: All A26 engines built prior to 11/2019

CHANGE LOG

6/27/2024 - Clarified campaign is no longer paused
12/4/2023 - All PWR CYL campaigns were reactivated

9/21/2023- Included note on pausing campaigns. Included inspection times

9/18/2023 - Navistar has temporarily paused proactive repair activity due to supplier constraints

8/31/2023- Included inspection summary for PWR CYL KITs

8/15/23 - Added SRTs for HX and HV

5/22/23 - Added quality hold alert to 2517649C93

4/4/2023 - Updated Proactive vs Reactive verbaige. Clarified completing 20504, 21505, and 22518 post repair. Added blurb to open case for torque
data

2/17/2023 - Updated Broken Links. Updated verbaige

11/07/2022 - Updated: Authorized Dealer List / Updated Repair Instruction Flow / Transition from Blue Tag to Warranty Return

05/17/2022 - Updated Authorized Dealer List

DESCRIPTION
The purpose of this article is to describe all aspects of the A26 Connecting Rod Replacement Repair Processes.
To address an A26 connecting rod supplier quality spill, Navistar is streamlining quality repair strategies to help avoid customer disturbance

Navistar is implementing connecting rod replacements which results in less downtime and damage avoidance.Navistar shipped Cylinder Kit Puller 12-
192-01 to high A26 traffic dealer locations.

SPECIAL TOOL(s) / SOFTWARE

Tools listed below should be available and in good working condition prior to the start of the repair to avoid any delays in the completion of the work

Note: Other tools are required, refer to the service manual for the detailed list
Note: Always ensure calibration on Digital Torque Wrench is up to date

[ Tool Description [TootNumber _||References |
[ Cylinder Kit Puller Tool [12-192-01 |[ TL1200005 |
[ Snap-On Digital Torque Wrench | CTECH3FR250A\| 1K1201391 |
| Cylinder Head Lifting Bracket [ 12-342-03 | |
[ Engine Barring Tool [ 12-102-02 l |
[ Socket, ConRod Bolt (E18 TORX) || ZTSE4835 l |
[ Socket, Head Bolt (E24 TORX) _|[ZTSE4787 l |
[ Head Bolt Bottoming Tap [ ZTSE4855 l |
[ Gauge, Cylinder Liner Height [ZTSE2515A __ || |
[ Liner Protrusion Clamps [ZTSE4825 l |

SERVICE PARTS INFORMATION

The following parts are required for Connecting Rod Replacement Repair:

NOTE: Week of 5/15/23, 2517649C93 was placed on a quality hold. Inventory will be corrected and revised to 2517649C94.

Note: ALL Dealer inventory should be verified prior to installation - The case analyst will provide inspection sheet within the case
file

+ 2517649C93 : Disassemble and inspect all sub-components (Orientation for Piston Rings, Retainer Clips, and Connecting

Rod)
+ 2517649C94 : Inspect orientation of retainer clips and connecting rod

Kit -

Description |P@rt Number | Quantity | Notes

Kit, Cylinder

Head

Removal & |2517038c92 | 1

Installation

* Proactive Campaigns

refer to the parts listed

Kit, Power Repair 6 for specific VIN

Cylinder Dependent + Engine symptoms &
codes refer to
2517649C93

Gasket, Oll tsoq3425c2 1

Pan

Seal, O-

Ring (Pick 06569361612), 1

lup tube)

Kit, Oil

Filter 3007498C94 | 1

NOTE: Reduced Power Cylinder Kit 2522946C91 will require QTY 1 of 62965010534 (2522946C92 contains 62965010534 - See table below)
NOTE: CYLINDER HEAD R&l Kit 2517038C91 will require QTY 1 of 3014964C91 (2517038C92 contains 3014964C91 - See table below)
NOTE: To install Assembled Power Cylinder Assembly, Red Cylinder Cap Plug 2523516C1 is available in PDC - It is reusable

Below table displays the differences between the parts kits:

a Part
Description Number

[ [ |
1

RETAINER,
PISTON PIN
ROD My

ASSEMBLY,
CONNECTING
BEARING, \
CONNECTING |

Notes Visual Description Instructions

n

L ‘
N 4328817R1
LOWER -

STANDARD | 2 <

O-RING, 4
CYLINDER
SLEEVE 139.4

X3.95 CD

Power Cylinder Disassembly:
Assembly is Pre- Power
Assembled with

»

Kit, Reduced Power
Cylinder

ROD UPPER
SHELL,
BEARING

2522946C92

-

e

A26 Power Cylinder 2517649093.

Kit (Assembled) Now
Components Removal

Power Cylinder

A26 Assembly is Pre- Assembly: 2017,
Assembled with A26 Manual>

REMANUFACTURED Age Manual

POWER CYLINDER | 9012252R91]New Components linder

KIT (Assembled) Assembly >
Remanufactured Installation

Piston

Contains '
Components
Required for
Cylinder Head
Removal and

Installation (Ral)

Reduced Cylinder
Head Removal Kit, | 2517038C92
R&d

Contains
Components
251761192) Required for
Cylinder Head
Replacement

Full Cylinder Head
Removal Kit