23502 Insufficient Roof Panel Joint Strength – 2022-2023 IC Bus CE, & 2022-2023 IC RE Transit Buses

SEOCONTENT-START

SERVICE PROCEDURE
SUBJECT: SAFETY RECALL
23502
APRIL 2023
Roof Lining Joints on certain 2022 and 2023 IC Bus® CE and RE Series commercial bus models built 09/01/2021 thru 12/15/2022. CUSTOMER LETTER Print ready (PDF file) copy of the Customer Letter DEFECT DESCRIPTION @ □ □
APR O 3 2023
Compliance Dept One or more joints that connect the roof top sheets may have not been properly secured to the roof bow supports. In the event of an accident involving the roof of the bus, the roof top sheets may separate and not protect the occupants sufficiently, increasing the risk of possible injury or death. MODELS INVOLVED This safety recall involves certain 2022 and 2023 IC Bus® CE and RE Series commercial bus models built 09/01/2021 thru 12/15/2022.
ELIGIBILITY
This procedure applies ONLY to vehicles marked in the International® Service Portal5M with Safety Recall 23502. Also complete any other open campaigns listed on the Service Portal at this time. TOOL INFORMATION
Description
Scaffold or safety harness Tape measure
Slow speed drill
#21 drill bit 0.1590 in (4.0386 mm) diameter
Drill bit stop
Center punch and hammer
Table 1 Tools Information
Tool Number
None None None None None None VEHICLE RECALL 23502
© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
1 PARTS INFORMATION NOTE: There are 50 screws per box and one box can repair two roof top sheet joints. Depending on the length and / or roof hatch configuration of the bus being repaired, you may need up to five boxes per bus. NOTE: These screws are AB #10-16 x 3/4 in Cross Recessed Pan Head, have a sealer applied, and have the heads painted white or yellow to blend with the color of the roof. Part Number 8900142R91 8900143R91 Part Description
AB #10-16 x 3/4 in YELLOW NSBC W/FISHER COMPOUND
AB #10-16 x 3/4 in WINTER WHITE W/FISHER COMPOUND Quantity As Needed As needed Table 2 Parts Information SERVICE PROCEDURE WARNING! To prevent personal injury and/ or death, or property damage, 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 property damage, 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. IMPORTANT: Portions of this repair procedure must be performed on the roof of the bus. Please refer to the Warnings depicted in this document and consult your facility’s OSHA guidelines related to safety requirements before performing this procedure. VEHICLE RECALL 23502
@2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 2 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. Safely position scaffolding or safety harness over bus. \ / Figure 1. Front Entrance Door Rivets 1. Row of rivets
2. Front cap panel NOTE: Do not measure the row of rivets (Figure 1, Item 1) of the roof top sheet above the entrance door to the front cap (Figure 1, Item 2); it is not part of the inspection procedure. VEHICLE RECALL 23502
e 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 3 1 2 3
\J· _I
I …..
Figure 2. Measurement Guidelines – Drip Rail & Top Sheet 1. Back edge of rearmost top sheet
2. Measurement – rearmost top sheet to forward row of rivets
3. Measurement – 20 in (508 mm) up from drip rail
4. Top of drip rail • • ———-•—-• •
1 • • •
• • 2 • • • 3 • •
• •
• • •
• • I :I —4 Figure 3. Measurement Guidelines – Rear Edge of Top Sheet to Front Row of Rivets 1. Back edge of rearmost top panel
2. Forward row of rivets on mating top panel
3. Measurement to centerline of roof
4. Centerline of forward row of rivets VEHICLE RECALL 23502
© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 4 NOTE: The inspection requires measuring the rear edge of the roof top sheet metal, not the sealant edge, to the forward row of rivets of the next forward joint. NOTE: The inspection procedure is only required on one side of the bus. If a repair is required, the complete joint is to be repaired. NOTE: Start with the rearmost top sheet, and all measurements must start approximately 20 in (508 mm) up, at least 9 rivets up, from the top of the drip rail to the top centerline of the roof (Figure 3, Item 3). 6. Measure and record roof top panels starting at rearmost top panel of bus (Figure 2, Items 1 & 2) using a tape measure. Refer to following detailed instructions: a) Measure up 20 in (508 mm) (Figure 2, Item 3) from top of drip rail (Figure 2, Item 4), approximately 9 rivets. b) Measure from rear edge of top panel (Figure 3, Item 1) to centerline of forward row of rivets (Figure 3, Item 4) on next joint on each panel and not from sealant edge. c) Measure all rivets to centerline of roof (Figure 3, Item 3). NOTE: Roof top sheets may vary in length, and maximum dimensions must not exceed 30.25, 39.25, 57.25, or 44.75 in for each roof top sheet you will measure. Roof Spacing Maximum Dimension (in) Single Bow Sheet Single Bow Sheet plus 9 in
Double Bow Sheet RE Rear Sheet 30.25 in
39.25 in 57.25 in
44.75 in Table 3 Maximum Roof Dimension 7. Determine if measurements meet or exceed maximum dimension. a) If measurement is less than or equal to maximum dimension, repair of joint(s) is not required. b) If measurement is greater than maximum dimension, repair on panel(s) is required. VEHICLE RECALL 23502
© 2023 Navistar, Inc. All rights reserved. AU marks are trademarks of their respective owners. 5 8. Determine if bus has a roof hatch overlapping a roof joint row of rivets. a) If top panel does not have a roof hatch overlapping a roof joint row of rivets and does not exceed maximum dimension, repair of joint is not required. b) If top panel has a roof hatch covering rear row of rivets and exceeds maximum dimension, repair on panel is required. Perform Step 9 and 10. • •
• •
• 2 • • •
• • •0 • • • • • • • • • •0 • • • • • • • • •0 • •
-= Figure 4. Noncompliant Roof Bow Screw Locations 1. Screw locations
2. Existing rivets VEHICLE RECALL 23502
@ 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 6 I
I 0000477523
Figure 5. Correct and Incorrect Seal 1. Correct seal
2. Incorrect seal NOTE: In line with the rear most row of rivets of the noncompliant joint, approximately 24 screws will need to be added. Screws to be added between every other rivet. NOTE: These screws are self-tapping and can easily be stripped. Refer to Figure 6 for correct (Figure 5, Item 1) and incorrect (Figure 5, Item 2) seal. If incorrect seal is made, install new screw to create correct seal. 9. Install self-sealing screws (Figure 4, Item 1) between every other rivet (Figure 4, Item 2) into noncompliant roof bow. Refer to following detailed instructions: a) Starting at 20 in (508 mm) up from drip rail, mark correct location between every other rivet (Figure 4, Item 1) to be punched and drilled on panel using a marker. b) Punch location for each hole to be drilled on panel using hammer and center punch. c) Install #21 drill bit 0.1590 in (4.0386 mm) diameter into drill. d) Install and set drill stop to 1/2 in (12.7 mm) depth. VEHICLE RECALL 23502
© 2023 Nav[star, Inc. All rights reserved. AUmarks are trademarks of their respective owners. 7 e) Drill holes through joint, apply cutting oil to metal surface being drilled. f) Remove metal shavings from roof and drill bit using shop vacuum. g) Clean surface with non-oil-based cleaner and wipe dry. h) Install self-sealing screws. See Figure 5 for correct seal. i) Tighten screws until head is fully seated. 2 DX A3/BBlliWJ Figure 6. Noncompliant Roof Bow – Roof Hatch Screw Locations 1. Screw locations
2. Existing rivets
NOTE: If roof hatch is covering a row of rivets by a noncompliant joint, approximately 52 screws will be needed when they are installed every 1/2 in (12.7 mm) and staggered along the forward edge of roof hatch. 10. Install self-sealing screws (Figure 6, Item 1) into roof between roof hatch and forward row of rivets (Figure 6, Item 2) every 1/2 in (12.7 mm) near noncompliant roof bow. Refer to following detailed instructions: a) Mark correct location for each hole 1/2 in (12.7 mm) apart and staggered to be punched and drilled on panel using a marker. b) Punch location for each hole to be drilled on panel using hammer and center punch. c) Install #21 drill bit 0.1590 in (4.0386 mm) diameter into drill. VEHICLE RECALL 23502
© 2023 Navistar, Inc. Allrights reserved. All marks are trademarks of their respective owners. 8 d) Install and set drill stop to 1/2 in (12.7 mm) depth. e) Drill holes through joint and apply cutting oil to metal surface being drilled. f) Remove metal shavings from roof and drill bit using shop vacuum.
g) Clean surface with non-oil-based cleaner and wipe dry. h) Install self-sealing screws. See Figure 5 for correct seal. i) Tighten screws until head is fully seated. Be careful not to overtighten self-sealing screws. 11. Once all noncompliant joints have been repaired, carefully remove scaffolding or safety harness. 12. Remove wheel chocks. END OF SERVICE PROCEDURE LABOR INFORMATION NOTE: Time to set up scaffolding and/or safety harness should be submitted as T-time and attach technician comments and time punches with the claim submission. Operation Number
A40-23502-1 A40-23502-2 A40-23502-3 A40-23502-4 Description
Inspect All Joints Repair One Joint
Repair each additional joint; as needed
Repair joint with roof patch; as needed Time
0.6 hrs.
0.5 hrs.
0.4 hrs.
1.0 hrs. Table 4 Labor Information VEHICLE RECALL 23502
@2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 9 CAMPAIGN IDENTIFICATION LABEL Each vehicle corrected in accordance with this campaign must be marked with a CTS-1075 Campaign Identification Label. Complete the label and attach on a clean surface next
to the vehicle identification number (VIN) plate. COMPLETED service Locauon Code, ADMINISTRATIVE / DEALER RESPONSIBILITIES WARRANTY CLAIMS Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to Safety Recall 23502. 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, a barrel of oil, or a tube of silicone) should be prorated for the cost of the individual pieces / amount used during each repair. GROUP – Enter number ..,_, GROUP
I I I I NOUN
I I C WARR. TP PAD NOUN – Leave blank I –
C (CAUSE) – Enter either 1, 2, 3. (See below)
1. Inspected (No repair required).
2. Inspected and repaired.
3, Defective part from parts stock. –
WARRANTY – (Warranty Code) Enter 40. ..:: TYPE PART – Enter P for type part causing failure. -:: PAD – Enter ‘K)() – ocooo.7910 VEHICLE RECALL 23502
@ 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 10 UNITED STATES AND POSSESSIONS The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle that is subject to a vehicle recall campaign must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within 60 days after a tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within 60 days, the owner may be entitled to replacement with an identical or reasonable equivalent vehicle at no charge, or to a refund of the purchase price less a reasonable allowance for depreciation. Dealers must correct all vehicles subject to this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership, from this time forward. Dealers should proceed immediately to make necessary correction to units in inventory. All inventory vehicles subject to this recall campaign must be corrected prior to sale, transfer or delivery. If vehicles have been sold or transferred and you are in receipt of Customer Notification Letters and Authorization for Recall Service cards for those vehicles, the transfer location or customer must be notified immediately from your dealer location. Dealers must make every effort to promptly schedule an appointment with each owner to repair his or her vehicle as soon as possible. However, consistent with the customer notification, dealers are expected to complete the repairs on the mutually agreed upon service date. Dealers involved in the recall process will be furnished a listing of owner names and addresses to enable them to follow up with owners and have the vehicles corrected. Use of this listing must be limited to this campaign because the list may contain information obtained from state motor vehicle registration records, and the use of such motor vehicle registration data for purposes other than this campaign is a violation of law in several states. CANADA Dealers must correct all vehicles subject to this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership, from this time forward. Dealers should proceed immediately to make necessary correction to units in inventory. All inventory vehicles subject to this recall campaign must be corrected prior to sale, transfer or delivery. If vehicles have been sold or transferred and you are in receipt of Customer Notification Letters and Authorization for Recall Service cards for those vehicles, the transfer location or customer must be notified immediately from your dealer location. VEHICLE RECALL 23502
© 2023 Navlstar,.Inc. All rights reserved. All marks are trademarks of their respective owners. 11 Dealers must make every effort to promptly schedule an appointment with each owner to repair his or her vehicle as soon as possible. However, consistent with the customer notification, dealers are expected to complete the repairs on the mutually agreed upon service date. Dealers involved in the recall process will be furnished a listing of owner names and addresses to enable them to follow up with owners and have the vehicles corrected. Use of this listing must be limited to this campaign because the list may contain information obtained from state motor vehicle registration records, and the use of such motor vehicle registration data for purposes other than this campaign is a violation of law in several states.
EXPORT
Export Distributors should proceed immediately to make necessary correction to units in inventory. All inventory vehicles subject to this recall campaign must be corrected prior to sale, transfer or delivery. If vehicles have been sold or transferred and you are in receipt of Customer Notification Letters and Authorization for Recall Service cards for those vehicles, the transfer location or customer must be notified immediately from your distributor location. Export Distributors are to submit warranty claims in the usual manner making reference to this recall number. Export Distributors are expected to provide full cooperation and follow-up with respect to this important subject matter. If you have any questions or need further assistance, please contact the Regional Service Manager at your regional office. NAVISTAR, INC.
VEHICLE RECALL 23502
© 2023 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
12

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IC Bus, LLC oll.,’GiA/AI 1(£I cT£l>
l- Tr/3/<. &D°=,rn® 2701 Navistar Drive &O [brn@
Lisle, IL 60532 USA
navistar.com APR O 3 2023
By: f g:’ff.f. 1′- APR I 2 2023
By: f;f? t’l : 1-;_ A llf.lWBlMI COMPANY
IMPORTANT SAFETY RECALL 23502 NHTSA RECALL NO. 23V-066
This notice applies to your vehicle identified on the enclosed card.
Dear IC Bus Customer,
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
IC Bus has decided that a defect which relates to motor vehicle safety exists in certain 2022 and 2023 CE & RE commercial bus models built 09/01/2021thru12/15/2022. REASON FOR THIS RECALL
One or more joints that connect the roof top sheets may have not been properly secured to the roof bow supports.
RISK TO MOTOR VEHICLE SAFETY
In the event of an accident involving the roof of the bus, the roof top sheets may separate and not protect the occupants sufficiently, increasing the risk of injury or death. DEFECT REMEDY
The repair will involve measuring the rivet location for each joint and if they are not within specification, screws will be added to the rear row of rivets to all joints that are out of spec ication. Dealers have parts and instructions to repair your vehicle. The repair will be performed free of charge and take approximately 30 minutes to 2 hours to complete, depending on your specific bus configuration.
ACTIONS YOU SHOULD TAKE
If you own this vehicle, please schedule an appointment with any IC Bus dealer to have your vehicle repaired. You can find your nearest dealer by using the dealer locator at http://www.icbus.comor by calling 1-800-448-7825.
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
APRIL 2023
02/16/2022 thru 04/13/2023. Present your original repair paperwork and proof of payment to any IC Bus dealer and your eligibility will be reviewed. You may also submit a claimusing 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 federall regulations.
If you do not own this vehicle, please fill out and return mail the enclosed card so that you will not be contacted againabout this recall.
IF YOU NEED ASSISTANCE
lf you believe that IC Bus 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.
IC Bus requests your prompt attention and patience regarding the correction of this defect and apologizes for any inconvenience this may cause you.
IC Bus, LLC

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-066
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. FEB 09, 2023 NHTSA Recall No. : 23V-066 Manufacturer Recall No. : 23502 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 115 Estimated percentage with defect : 90 %
Vehicle Information :
Vehicle 1 : 2022-2023 IC Bus CE CB
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by all models built within the suspect build dates.
• The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification.
• The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 46 CE commercial buses in the suspect population.
Production Dates : SEP 01, 2021 – DEC 15, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2022-2023 IC Bus RE CB
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by all models built within the suspect build dates.
• The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification.
• The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 69 RE commercial buses in the suspect population.
Production Dates : SEP 16, 2021 – NOV 03, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-066 Page 2 Description of Defect :
Description of the Defect : One or more joints that connect the roof top sheets may not meet the requirement of Federal Motor Vehicle Safety Standard No. 221, S5.1. General Performance Requirements for S.6.1.1, S.6.1.2, and S6.2, S6.2 (a), (b), and (c).
FMVSS 1 : 221 – School bus body joint strength FMVSS 2 : NR
Description of the Safety Risk : In the event of an accident involving the roof of the bus, roof top sheets that do not conform to all the requirements of FMVSS 221 may separate and not protect the occupants sufficiently, increasing the risk of possible injury or death.
Description of the Cause : A machine that is not forming the roof bow supports correctly is currently under investigation for root cause. Identification of Any Warning
that can Occur : Water leaks into the passenger compartment of the bus may occur. Involved Components : Component Name 1 : Roof Bow
Component Description : Roof Bow created in manufacturing process. Component Part Number : NPN Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
• 01/19/2023 – Navistar Manufacturing initiated an investigation of a leaking roof at water test and noticed insufficient overlap of the roof sheeting.
• 01/19/2023 and 01/20/2023 – Navistar Manufacturing audits the processes from bow former through topping sheet installation.
• 01/24/2023 – Navistar Manufacturing quarantines buses at the assembly plant and contains the issue in manufacturing. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-066
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
• 1/25/2023 When testing compliance to FMVSS 221, Navistar pull tests of three suspect roof joints did not meet the 6,241 pound pull test requirement. Joints separated at 5,645 and 5,026 pounds.
• 01/31/2023 – Navistar Manufacturing meets with Compliance to review pull test results and initiate investigation to determine the impact to IC buses.
• 02/02/2023 – Navistar determines the suspect population and declares a Non Compliance recall.
Description of Remedy :
Description of Remedy Program : • The remedy will involve measuring the rivet location for each joint
and if they are not within specification, 24 screws will be added to the rear row of rivets to all joints that are out of specification.
• 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 : Identify How/When Recall Condition was Corrected in Production : Buses built during this time frame; the bow bender was not forming the roof bows correctly. Buses built prior to this time; the bow bender was producing bows that were formed correctly.
01/23/2023 – Navistar Manufacturing hand oil mists the raw material prior to installation into the roof bow forming machine and rotates the roof bow 180-degrees during installation to the bus chassis which positions the roof bow back into the topping sheet instead of away from the topping sheet. Recall Schedule :
Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be
mailed by 04/03/2023.
Planned Dealer Notification Date : APR 03, 2023 – APR 03, 2023
Planned Owner Notification Date : APR 03, 2023 – APR 03, 2023
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-066
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. MAR 09, 2023 NHTSA Recall No. : 23V-066 Manufacturer Recall No. : 23502 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 115 Estimated percentage with defect : 90 %
Vehicle Information :
Vehicle 1 : 2022-2023 IC Bus CE CB
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by all models built within the suspect build dates.
• The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification.
• The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 46 CE commercial buses in the suspect population.
Production Dates : SEP 01, 2021 – DEC 15, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2022-2023 IC Bus RE CB
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by all models built within the suspect build dates.
• The suspect build dates were determined by measurements made to multiple buses and manufactured in multiple months and years until buses were determined to have roof sheet joints within specification.
• The buses in the suspect population were built within the suspect build dates and all other models not subject to this Non-compliance were built outside of the suspect build dates. There are 69 RE commercial buses in the suspect population.
Production Dates : SEP 16, 2021 – NOV 03, 2022
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-066 Page 2 Description of Defect :
Description of the Defect : One or more joints that connect the roof top sheets may not have been properly secured to the roof bow supports.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : In the event of an accident involving the roof of the bus, roof top sheets may separate and not protect the occupants sufficiently, increasing the risk of possible injury or death.
Description of the Cause : A machine that is not forming the roof bow supports correctly is currently under investigation for root cause. Identification of Any Warning
that can Occur : Water leaks into the passenger compartment of the bus may occur. Involved Components : Component Name 1 : Roof Bow
Component Description : Roof Bow created in manufacturing process. Component Part Number : NPN Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
• 01/19/2023 – Navistar Manufacturing initiated an investigation of a leaking roof at water test and noticed insufficient overlap of the roof sheeting.
• 01/19/2023 and 01/20/2023 – Navistar Manufacturing audits the processes from bow former through topping sheet installation.
• 01/24/2023 – Navistar Manufacturing quarantines buses at the assembly plant and contains the issue in manufacturing.
• 1/25/2023 When testing compliance to FMVSS 221, Navistar pull tests of three suspect roof joints did not meet the 6,241 pound pull test requirement. Joints separated at 5,645 and 5,026 pounds. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-066
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
• 01/31/2023 – Navistar Manufacturing meets with Compliance to review pull test results and initiate investigation to determine the impact to IC buses.
• 02/02/2023 – Navistar determines the suspect population and declares a Non Compliance recall.
• 03/02/2023 – Navistar reclassifies 23502 to a safety recall based on determination by Navistar Compliance and Certification Compliance that FMVSS 221 and CMVSS 221 apply to school bus only.
Description of Remedy :
Description of Remedy Program : • The remedy will involve measuring the rivet location for each joint
and if they are not within specification, 24 screws will be added to the rear row of rivets to all joints that are out of specification.
• 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 : Identify How/When Recall Condition was Corrected in Production : Buses built during this time frame; the bow bender was not forming the roof bows correctly. Buses built prior to this time; the bow bender was producing bows that were formed correctly.
01/23/2023 – Navistar Manufacturing hand oil mists the raw material prior to installation into the roof bow forming machine and rotates the roof bow 180-degrees during installation to the bus chassis which positions the roof bow back into the topping sheet instead of away from the topping sheet. Recall Schedule :
Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be
mailed by 04/03/2023.
Planned Dealer Notification Date : APR 03, 2023 – APR 03, 2023
Planned Owner Notification Date : APR 03, 2023 – APR 03, 2023
* NR – Not Reported

SEOCONTENT-END