2002 International 4200: complaints, problems and recalls

Reported: 2002-03-22 (March 22, 2002)

CERTAIN TRUCKS EQUIPPED WITH ENGINE STARTERS (CODE 08WWN OR 08WWP) BUILT BY LEECE-NEVILLE. THESE STARTERS HAVE A DEFECTIVE TERMINAL ADAPTER STUD. THE STUD IS USED ONLY AT THE POSITIVE BATTERY CONNECTION TO THE STARTER SOLENOID. IT WAS DESIGNED TO BE SCREWED ON OVER THE EXISTING STUD TO INCREASE THE STUD DIAMETER TO ACCOMMODATE THE LARGER SIZE OF THE POSITIVE BATTERY CABLE TERMINAL. THE ADAPTER STUD WAS WEAKENED WHEN THE HOLE WAS DRILLED TOO DEEP.

Consequence: THIS COULD LEAD TO A DIRECT ELECTRICAL SHORT TO THE BATTERIES. IF THE STUD BREAKS OFF, THE POSITIVE BATTERY CABLE COULD SHORT DIRECTLY TO GROUND, WHICH CAN GENERATE HEAT AND SPARKS CAUSING A FIRE.

Remedy: DEALERS WILL REPLACE THE ADAPTER STUD. OWNER NOTIFICATION BEGAN APRIL 15, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2002-03-22 (March 22, 2002)

ON CERTAIN TRUCKS, THE COTTER PIN THAT GOES THROUGH THE DRAG LINK BALL STUD AT THE CONNECTION TO THE PITMAN ARM IS MISSING. THIS PIN PREVENTS THE CASTLE NUT FROM LOOSENING.

Consequence: IF THE NUT LOOSENS AND COMES COMPLETELY OFF THE DRAG LINK BALL STUD, THE DRAG LINK COULD DETACH RESULTING IN A LOSS OF STEERING CONTROL.

Remedy: DEALERS WILL INSPECT THE VEHICLE AND INSTALL A COTTER PIN IF IT IS MISSING. OWNER NOTIFICATION BEGAN APRIL 15, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2002-07-26 (July 26, 2002)

ON CERTAIN SCHOOL BUSES AND HEAVY DUTY TRUCKS BUILT WITH INTERNATIONAL VT365 ENGINES AND MANUFACTURED AT INTERNATIONAL DIESEL OF ALABAMA. THE INJECTOR DRIVER MODULES (IDM) BUILT FOR THE VT365 ENGINES COULD HAVE MISSING VIBRATION DAMPING/RETENTION SHELLS AND A MISSING HOT-MELT PROCESS ON THE DC/DC BOARDS.

Consequence: THE MISSING SHELLS COULD ALLOW THE LARGER ELECTRONIC COMPONENTS TO BECOME LOOSE AND POSSIBLE BREAK OFF INSIDE THE MODULE DURING ENGINE OPERATION. DEPENDING ON WHAT ELECTRICAL COMPONENT COMES OFF, THE EFFECT ON ENGINE OPERATION COULD RESULT IN ROUGH RUNNING, LOSS OF POWER, NO START, OR IN THE MOST SEVERE CASE, IMMEDIATE ENGINE SHUT DOWN WITHOUT WARNING, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE IDM MODULES. OWNER NOTIFICATION BEGAN OCTOBER 28, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2002-09-20 (September 20, 2002)

ON CERTAIN MEDIUM AND HEAVY DUTY TRUCKS BUILT WITH DRIVELINE PARKING BRAKE CODES 04GAR, THE PARKING BRAKE ASSEMBLY MAY NOT HOLD THE VEHICLE IN POSITION WHEN SET. FACTORS CONTRIBUTING TO THIS POSSIBILITY ARE AS FOLLOWS: (1) CRACKED OR BROKEN CAMS; (2) LOOSE OR BROKEN ANCHOR BOLTS; (3) INITIAL SHOE DIAMETER NOT SET PROPERLY DURING ASSEMBLY, WHICH CAN LEAD TO PROGRESSIVE COMPONENT DAMAGE; (4) BENT ADJUSTER LEVERS THAT CANNOT FUNCTION; OR (5) AUTOMATIC ADJUSTER CABLES THAT ARE DISCONNECTED.

Consequence: IF THE PARKING BRAKE DOES NOT FUNCTION PROPERLY, THE VEHICLE COULD ROLL, WITHOUT WARNING, AFTER THE PARKING BRAKE LEVER HAS BEEN SET, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE CAM, LEVER, AND BOLT. OWNER NOTIFICATION BEGAN DECEMBER 30, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2003-02-25 (February 25, 2003)

ON CERTAIN SCHOOL AND TRANSIT BUSES BUILT WITH BOSCH ZERO OFFSET PIN SLIDE (ZOPS) HYDRAULIC DISC BRAKES, THE ZOPS HYDRAULIC DISC BRAKES MAY EXPERIENCE CALIPERS STICKING IN THE APPLIED POSITION, WHICH CAN RESULT IN EXCESSIVE OR ABNORMAL HEAT GENERATION AT ONE OR MORE OF THE BRAKES.

Consequence: THE COMBINATION OF THE FOLLOWING FACTORS MAY COLLECTIVELY RESULT IN AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY: POTENTIAL FIRE AT A WHEEL END, HIGH INCIDENT RATES OF STUCK CALIPERS, AND EVACUATION AND CONTAINMENT CONCERNS RELATING TO MULTIPLE PASSENGERS.

Remedy: INTERNATIONAL WILL NOTIFY ITS CUSTOMERS AND REPAIR THE BUSES FREE OF CHARGE. THE RECALL BEGAN OCTOBER 29, 2004.

Reported: 2003-08-27 (August 27, 2003)

CERTAIN HEAVY DUTY TRUCKS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS." THE PRIMARY AND SECONDARY AIR SUPPLY HOSES FROM THE FOOT VALVE TO THE PRIMARY AND SECONDARY AIR TANKS WERE IMPROPERLY ROUTED AT THE TANK.

Consequence: IF THE PRIMARY AIR CIRCUIT IS DAMAGED, THE BRAKES WILL NOT APPLY WHEN THE BRAKE PEDAL IS DEPRESSED INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT AND REPAIR VEHICLES. OWNER NOTIFICATION WILL BE COMPLETED BY OCTOBER 3, 2003. OWNERS WHO TAKE THEIR VEHICLE TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT INTERNATIONAL AT 1-800-448-7825.

Reported: 2003-10-22 (October 22, 2003)

ON CERTAIN TRUCKS EQUIPPED WITH V8 ENGINES AND AIR BRAKES OR AIR OPERATED PARK BRAKES, A STAND-OFF BRACKET WAS NOT INSTALLED. THE BRACKET SUPPORTS THE COPPER AIR COMPRESSOR DISCHARGE TUBE. NORMAL VEHICLE AND ENGINE VIBRATION CAN CAUSE THE UNSUPPORTED COPPER TUBE TO FAIL AT OR NEAR THE AIR COMPRESSOR CONNECTION.

Consequence: A FAILED COMPRESSOR DISCHARGE TUBE COULD DEPLETE THE AIR SYSTEM AND MAY CAUSE THE PARKING BRAKES TO APPLY. THIS CONDITION COULD CAUSE THE VEHICLE TO SLOW DOWN OR STOP UNEXPECTEDLY AND RESULT IN A CRASH.

Remedy: DEALERS WILL INSPECT AND REPAIR THE STAND-OFF BRACKET AS NECESSARY. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING DECEMBER 2003. OWNERS SHOULD CONTACT INTERNATIONAL TRUCK AT 1-800-448-7825.