22516 – Battery Cables Grounded Incorrectly – 2018-2021 International LoneStar & 2016-2021 LT

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SERVICE PROCEDURE 22516 SEPTEMBER 2022 SUBJECT: SAFETY RECALL ©~ □~□~ SEP 21 2022 Compliance Dept ~£□ °=~® SEP 2 6 2022 By: f P.tJf.(!.~1(flf. Alternator Ground Location on certain International® LT® Series trucks built 12/15/2015 thru 09/07/2020 and 2018 thru 2021 International@ LoneStar® Series trucks built 07/21/2017 thru 08/24/2020 with Cummins® engines, feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), and feature codes 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter) CUSTOMER LETTER Print ready (PDF file) copy of the Customer Letter DEFECT DESCRIPTION During high electrical demand, the cables that ground the batteries to the vehicle frame can carry the full system current and may result in excessively hot battery ground cables and in some cases, battery post separation. Excessively hot battery ground cables can cause personal injury during battery maintenance repairs or a battery post that separates from the battery can result in engine shut down without warning and increase the risk of a vehicle crash. MODELS INVOLVED This Safety Recall involves certain International® LT® Series trucks built 12/15/2015 thru 09/07/2020 and 2018 thru 2021 International® LoneStar® series trucks built 07/21/2017 thru 08/24/2020 with Cummins® engines, feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), and feature codes 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD {DC to AC power inverter). VEHICLE RECALL 22516 © 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 1 ELIGIBILITY This procedure applies ONLY to vehicles marked in the International® Service Portal5M with Safety Recall 22516. Also complete any other open campaigns listed on the Service Portal at this time. PARTS INFORMATION NOTE: There are two Parts kits for this campaign. One for vehicles built with No Idle HVAC and one for all others. Part Part Description Quantity Number 8900300R91 Kit, Alternator Ground Harness -With No Idle HVAC 1 8900301R91 Kit, Alternator Ground Harness – Without No Idle 1 HVAC NPN Softener Gel, Red Paint, and Blue Dielectric Grease As Needed 8900300R91 contains the following parts: Part Description Quantity Harness, Charging – With No Idle 1 Nut, Batterv Terminal 2 Strap, Cable Lock 17 Strap, Cable Lock 250 2 8900301 R91 contains the following parts: Part Description Quantity Harness, Charging-Without No Idle HVAC 1 Nut, Batterv Terminal 2 Strap, Cable Lock 17 Strap, Cable Lock 250 2 VEHICLE RECALL 22516 @ 2022 Navistar, Inc. AU rights reserved. All marks are trademarks of their respective owners. 2 SERVICE PROCEDURE WARNING! To prevent personal mJury 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, allow components in engine compartment to cool before servicing engine or vehicle. WARNING! To prevent personal mJury 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, remove the ground cable from the negative terminal of the battery batteries before disconnecting any electrical components. Always connect the ground cable last. 1. Park vehicle on flat surface. 2. Shift transmission to Park or Neutral and set parking brake. 3. Turn vehicle ignition to Key OFF position. 4. Install wheel chocks. 5. If necessary, remove driver-side vehicle side skirt. Refer to appropriate service information. 6. Disconnect and isolate negative battery cable from main vehicle battery. Discard nut. 7. Unlatch and open hood. 8. Remove driver-side front fender extension. Refer to appropriate service information for detailed instruction. VEHICLE RECALL 22516 © 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 3 9. Obtain access to the vehicle alternator and starter. CAUTION! To prevent damage to property or vehicle components, red sealant paint must be thoroughly softened and fully removed from bolt and threads. Avoid drip onto unwanted surfaces. Do not apply to rubber, wire insulation and the like, only metallic surfaces. 10. Using paint brush, apply gel softener onto all RED coated alternator and starter harness cable nuts and studs. NOTE: A longer set time will yield better results. 11. Allow gel softener to sit for 1 O to 15 minutes to soften the RED coating. 12. Remove air cleaner intake tube. Refer to appropriate service information for detailed instruction. 13. Record alternator harness routing and clipping points. 14. Remove and discard cable tie wraps securing alternator harness. 1 0000475736 Figure 1. Harness Retaining Bracket 1. Bracket 15. If necessary, reposition harness retaining bracket (Figure 1, Item 1 ). Save fasteners for reuse. VEHICLE RECALL 22516 © 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 4 NOTE: Ensure removal of RED gel coat on mating surface of eyelet connectors, nut, washers, threads, or any contact surface that may disrupt continuity. 16. Using a wire brush and rag remove RED coating from alternator and starter harness cable nuts and studs. 17. Remove alternator positive and negative terminal bolts/ nuts. Save fasteners for reuse. 1 Figure 2. Ground Cable Location 1. Alternator ground cable bolt 000047~737 18. Remove alternator ground cable bolt (Figure 2, Item 1) and nut at frame connection. Save bolt and nut for reuse. 19. Using bolt and nut removed in Step 18, secure engine block ground cable to frame and tighten nut to 23 lb-ft (31 N•m). 20. Disconnect positive and ground cable nuts at starter. Save nuts for reuse. 21. Disconnect alternator positive cable from starter. 22. Remove old alternator positive and negative cables from engine that were disconnected in previous step. VEHICLE RECALL 22516 e 2022 Navistar, Inc. All rights reserved. AU marks are trademarks of their respective owners. 5 2 0000475738 Figure 3. Alternator Cable Location 1. Alternator positive cable bolt 2. Alternator ground cable bolt 23. Starting at alternator, connect alternator positive (Figure 3, Item 1) and ground (Figure 3, Item 2) cables. Do not fully tighten retaining bolt/ nut at this time. 24. Using cable tie straps and original clipping points, route cables around front of engine and down to starter. Do not fully tighten cable tie straps at this time. 25. Connect alternator positive and ground cables to starter positive and ground terminals and install nuts. 26. Tighten starter ground nut to 32 lb-ft 43 N•m). 27. Tighten starter positive nut to 15 lb-ft (25 N•m). 28. Tighten alternator positive nut to 80-125 lb-in (9-14 N•m). 29. Tighten alternator ground bolt to 60-90 lb-in (6.8-10.2 N•m). 30. If necessary, position harness retaining bracket (Figure 1, Item 1) using previously-saved fastener. Tighten fastener securely. VEHICLE RECALL 22516 © 2022 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 6 NOTE: Ensure newly installed harness does not come into contact with adjacent components. 31. Tighten all cable tie straps securing alternator positive and negative harnesses. Remove and discard excess material. 32. Apply RED sealant paint and thoroughly coat frame bolt, alternator positive and negative terminals, starter positive and negative terminals. 33. Install air cleaner intake tube. Refer to appropriate service information for detailed instruction. 34. Using wire brush, electronic contact cleaner, and compressed shop air, clean negative battery terminal components. 35. Apply BLUE dielectric grease to battery terminal stud, negative battery cable ring terminal, and threads of new battery stud nut. 36. Using new battery stud nut, reconnect negative battery cable to negative terminal on main vehicle battery. 37. Using torque wrench, tighten battery stud nut to 12-15 lb-ft (16-20 N•m). 38. If necessary, install driver-side vehicle side skirt. Refer to appropriate service information. 39. Remove wheel chocks. END OF SERVICE PROCEDURE LABOR INFORMATION Operation Description Number A40-22516-1 Replace Alternator Positive and Ground Cables VEHICLE RECALL 22516 Time 1.4 hrs © 2022 Navistar, Inc. AU rights reserved. All mar1

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Navistar, Inc. 2701 Navistar Drive Lisle, IL 60532 USA navistar.com IMPORTANT SAFETY RECALL 22516 NHTSA RECALL NO. 22V-546 This notice applies to your vehicle identified on the enclosed card. Dear INTERNATIONAL® Customer, This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Navistar has decided that a defect which relates to motor vehicle safety exists in certain 2016 thru 2021 LT series trucks built 12/15/2015 thru 09/07/2020 and 2018 thru 2021 Lonestar series trucks built 07/21/2017 thru 08/24/2020 with Cummins engines, feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), and feature codes 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter). REASON FOR THIS RECALL During high electrical demand, the cables that ground the batteries to the vehicle frame can carry the full system current and may result in excessively hot battery ground cables and in some cases, battery post separation. RISK TO MOTOR VEHICLE SAFETY Excessively hot battery ground cables can cause personal injury during battery maintenance repairs or a battery post that separates from the battery can result in engine shut down without warning and increase the risk of a vehicle crash. DEFECT REMEDY The repair will involve replacing the alternator ground cable with a redesigned cable and relocating its terminal from the frame rail to the starter. Authorized repair locations have parts and instructions to repair your vehicle. The repair will be performed free of charge and take approximately one hour to complete. ACTIONS YOU SHOULD TAKE If you own this vehicle, please contact any INTERNATIONAL® dealer or a Love’s Truck Tire Care or [Ml&O~C@:[ID SEP 2 6 2022 . Ct?,,.,,/’£ /lf,UC A NAVISTAR COMPANY SEPTEMBER 2022 Speedco* location to have your vehicle repaired at no cost to you. You can find your nearest service location by calling 1-800-448-7825 or by using the service locator at http://www.internationaltrucks.com or https://www.loves.com . *Love’s and Speedco locations in Texas cannot perform warranty services. If you have already paid for repairs prior to this notice that corrected the defect, you may be eligible for reimbursement of certain repair expenses if they occurred 07/28/2021 thru 10/06/2022. Present your original repair paperwork and proof of payment to any INTERNATIONAL• dealer and your eligibility will be reviewed. You may also submit a claim using the enclosed Request for Reimbursement card. If you are the lessor of this vehicle, please forward a copy of this notice to the lessee within ten days to comply with federal regulations. If you do not own this vehicle, please fill out and return mail the enclosed card so that you will not be contacted again about this recall. IF YOU NEED FURTHER ASSISTANCE If you believe that Navistar has failed to remedy the defect without charge or within a reasonable time, please follow the procedure described in the Owner Assistance Guide section in your Owner’s Manual or call toll free 1-800-448- 7825. You may also submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave, SE, Washington, DC 20590; or call the toll free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800- 424-9153); or go to http://www.safercar.gov. Navistar requests your prompt attention and patience regarding the correction of this defect and apologizes for any inconvenience this may cause you. Navistar, Inc.

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-546 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : AUG 03, 2022 NHTSA Recall No. : 22V-546 Manufacturer Recall No. : 22516 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 8,483 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2016-2021 International LT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped Cummins engines and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter). • The inclusive dates of manufacture were determined by when this combination of features went into production through when Navistar began use of a revised alternator ground connection point. • The vehicles in the suspect population were built with Cummins engines, and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter) and all similar vehicles not subject to this recall were not equipped with these feature combinations. There are 8,223 LT series trucks in the suspect population. Production Dates : DEC 15, 2015 – SEP 07, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 22V-546 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2018-2021 International LoneStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped Cummins engines and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter). • The inclusive dates of manufacture were determined by when this combination of features went into production through when Navistar began use of a revised alternator ground connection point. • The vehicles in the suspect population were built with Cummins engines, and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter) and all similar vehicles not subject to this recall were not equipped with these feature combinations. There are 260 LoneStar series trucks in the suspect population Production Dates : JUL 21, 2017 – AUG 24, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : During high electrical demand, the cables that ground the batteries to the vehicle frame can carry the full system current and may result in excessively hot battery ground cables and in some cases, battery post separation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Excessively hot battery ground cables can cause personal injury during battery maintenance repairs or a battery post that separates from the battery can result in engine shut down without warning and increase the risk of a vehicle crash. Description of the Cause : The vehicle charging system wiring architecture resulted in the cables that ground the batteries to the frame rail to carry the majority of the alternator output current. Identification of Any Warning that can Occur : None Involved Components : Part 573 Safety Recall Report 22V-546 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Not Applicable Component Description : Not Applicable Component Part Number : Not Applicable Supplier Identification : Component Manufacturer Name : Not Applicable Address : NR NR Country : NR Chronology : Chronology Exceeds maximum characters allowed and will be submitted as a miscellaneous document. Description of Remedy : Description of Remedy Program : • The remedy will involve replacing the alternator positive and ground cables with redesigned cables and moving the alternator ground connection point from the frame rail to the starter. • Navistar’s plan for reimbursement of pre-notification remedies, on file with NHTSA and dated 05/06/2022, applies and reimbursement instructions will be included in the customer notification. How Remedy Component Differs from Recalled Component : The remedy alternator cables move the alternator ground cable to the starter ground connection where the recalled alternator cables connected the alternator ground cable to the vehicle frame. Identify How/When Recall Condition was Corrected in Production : 09/07/2020 – Navistar manufacturing changed the alternator ground location from the vehicle frame to the starter ground cable connection to correct a “noise” issue which was later found to also provide a second battery ground path, lessening the current thru the cables that ground the batteries to the vehicle frame. This corrected the overheated battery ground condition. Recall Schedule : Part 573 Safety Recall Report 22V-546 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 09/26/2022. Planned Dealer Notification Date : SEP 26, 2022 – SEP 26, 2022 Planned Owner Notification Date : SEP 26, 2022 – SEP 26, 2022 * NR – Not Reported

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-546 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : JUL 28, 2022 NHTSA Recall No. : 22V-546 Manufacturer Recall No. : 22516 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 8,483 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2021 International LoneStar Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped Cummins engines and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter). • The inclusive dates of manufacture were determined by when this combination of features went into production through when Navistar began use of a revised alternator ground connection point. • The vehicles in the suspect population were built with Cummins engines, and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter) and all similar vehicles not subject to this recall were not equipped with these feature combinations. There are 260 LoneStar series trucks in the suspect population Production Dates : JUL 21, 2017 – AUG 24, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 22V-546 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2016-2021 International LT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped Cummins engines and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter). • The inclusive dates of manufacture were determined by when this combination of features went into production through when Navistar began use of a revised alternator ground connection point. • The vehicles in the suspect population were built with Cummins engines, and feature codes 0008GXK, 0008GHJ and 0008GWY (high output alternators 275 to 375 amp output), 0016UZL and 0016VLN (no idle HVAC), or 008XDM and 008XLD (DC to AC power inverter) and all similar vehicles not subject to this recall were not equipped with these feature combinations. There are 8,223 LT series trucks in the suspect population. Production Dates : DEC 15, 2015 – SEP 07, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : During high electrical demand, the cables that ground the batteries to the vehicle frame can carry the full system current and may result in excessively hot battery ground cables and in some cases, battery post separation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Excessively hot battery ground cables can cause personal injury during battery maintenance repairs or a battery post that separates from the battery can result in engine shut down without warning and increase the risk of a vehicle crash. Description of the Cause : The vehicle charging system wiring architecture resulted in the cables that ground the batteries to the frame rail to carry the majority of the alternator output current. Identification of Any Warning that can Occur : None Involved Components : Part 573 Safety Recall Report 22V-546 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Not Applicable Component Description : Not Applicable Component Part Number : Not Applicable Supplier Identification : Component Manufacturer Name : Not Applicable Address : NR NR Country : NR Chronology : Chronology Exceeds maximum characters allowed and will be submitted as a miscellaneous document. Description of Remedy : Description of Remedy Program : • The remedy will involve replacing the alternator positive and ground cables with redesigned cables and moving the alternator ground connection point from the frame rail to the starter. • Navistar’s plan for reimbursement of pre-notification remedies, on file with NHTSA and dated 05/06/2022, applies and reimbursement instructions will be included in the customer notification. How Remedy Component Differs from Recalled Component : The remedy alternator cables move the alternator ground cable to the starter ground connection where the recalled alternator cables connected the alternator ground cable to the vehicle frame. Identify How/When Recall Condition was Corrected in Production : 09/07/2020 – Navistar manufacturing changed the alternator ground location from the vehicle frame to the starter ground cable connection to correct a “noise” issue which was later found to also provide a second battery ground path, lessening the current thru the cables that ground the batteries to the vehicle frame. This corrected the overheated battery ground condition. Recall Schedule : Part 573 Safety Recall Report 22V-546 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 09/26/2022. Planned Dealer Notification Date : SEP 26, 2022 – SEP 26, 2022 Planned Owner Notification Date : SEP 26, 2022 – SEP 26, 2022 * NR – Not Reported

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