23516 – ABS Light May Not Stay Illuminated – 2021-2024 IC Bus RE, 2022-2024 IC Bus CE, & IC Bus EV School Buses

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-371 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : MAY 25, 2023 NHTSA Recall No. : 23V-371 Manufacturer Recall No. : 23516 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 19,376 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2024 IC Bus CE School Bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with feature code 04AZS or 04AZY (Air Brake, Bendix Anti-Lock Brake system [ABS] with Electronic Stability Program [ESC] and Automatic Traction Control [ATC]); software versions ROM 4.1 or ROM 5.1. • The inclusive dates of manufacture were determined by when Navistar began the use of feature codes 04AZS and 04AZY with software versions ROM 4.1 or ROM 5.1 through the date the software issue was corrected in production with updated software versions ROM 4.2 and ROM 5.2. • The vehicles in the suspect population were built with feature codes 04AZS or 04AZY and all similar vehicles not subject to this recall were not built with feature codes 04AZS or 04AZY. There are 18,293 CE school buses in the suspect population Production Dates : OCT 05, 2020 – MAY 09, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-371 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2022-2024 IC Bus EV school bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : • The suspect population is identified by models equipped with feature code 04AZS or 04AZY (Air Brake, Bendix Anti-Lock Brake system [ABS] with Electronic Stability Program [ESC] and Automatic Traction Control [ATC]); software versions ROM 4.1 or ROM 5.1. • The inclusive dates of manufacture were determined by when Navistar began the use of feature codes 04AZS and 04AZY with software versions ROM 4.1 or ROM 5.1 through the date the software issue was corrected in production with updated software versions ROM 4.2 and ROM 5.2. • The vehicles in the suspect population were built with feature codes 04AZS or 04AZY and all similar vehicles not subject to this recall were not built with feature codes 04AZS or 04AZY. There are 179 EV school buses in the suspect population Production Dates : OCT 13, 2020 – MAY 03, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2024 IC Bus RE School bus Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : • The suspect population is identified by models equipped with feature code 04AZS or 04AZY (Air Brake, Bendix Anti-Lock Brake system [ABS] with Electronic Stability Program [ESC] and Automatic Traction Control [ATC]); software versions ROM 4.1 or ROM 5.1. • The inclusive dates of manufacture were determined by when Navistar began the use of feature codes 04AZS and 04AZY with software versions ROM 4.1 or ROM 5.1 through the date the software issue was corrected in production with updated software versions ROM 4.2 and ROM 5.2. • The vehicles in the suspect population were built with feature codes 04AZS or 04AZY and all similar vehicles not subject to this recall were not built with feature codes 04AZS or 04AZY. There are 904 RE school buses in the suspect population Production Dates : OCT 05, 2020 – MAY 08, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : The ABS indicator lamp does not conform to Federal Motor Vehicle Safety Standard (FMVSS) No. 121 6.2 (a). Specifically, the ABS indicator lamp does not remain activated when a malfunction exists, whenever the vehicle’s ignition switch is in the on (run) position, and the vehicle is in motion. Part 573 Safety Recall Report 23V-371 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 FMVSS 1 : 121 – Air brake systems FMVSS 2 : NR Description of the Safety Risk : If a fault exists with the ABS components and the lamp does not stay illuminated when the vehicle is in motion, during an event that requires ABS, a vehicle operator may not realize there is a fault with the ABS system, which can increase the risk of a vehicle crash that may result in property damage or personal injury. Description of the Cause : When there is an active ABS fault and when the vehicle is in motion, the brake system Electronic Control Unit (ECU) blink code function interfered with the ABS indicator lamp signal broadcast over the Controller Area Network (CAN) which causes the ABS indicator lamp to turn off. The ABS indicator lamp then re-illuminates when the vehicle comes to a stop. Identification of Any Warning that can Occur : A fault in the ABS system will also illuminate the Traction Control and Stability Control indicator lamps. These will remain illuminated while the vehicle is in motion. Involved Components : Component Name 1 : ECU ABS software Component Description : ECU ABS-8 ROM 4.1 and 5.1 software Component Part Number : ECU Z251843 to Z286098 and Z281032 to Z285654 Supplier Identification : Component Manufacturer Name : Bendix Commercial Vehicle Systems, LLC Address : 35500 Chester Rd Avon Ohio 44011 Country : United States Chronology : • 05/05/2023 – Navistar Research and Development (“R&D”) communicates to Compliance a potential defect with ABS indicator lamp functionality and initiates investigation. • 05/09/2023 – R&D, Regulatory Compliance, Supplier Quality, Service Engineering and Compliance review investigation results and evaluate impact of same on compliance with FMVSS 121 Section 6.2(a). • 05/10/2023 – Navistar quarantines all suspect vehicles at all vehicle manufacturing plants. • 5/15/2023 – Navistar Compliance receives confirmation from Bendix that a defect exists in a portion of Part 573 Safety Recall Report 23V-371 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 their ABS-8 ROM 4.1 and newer software that may affect Navistar vehicles. • 05/17/2023 – Navistar finalizes the suspect population. • 05/18/2023 – Navistar declares Non Compliance Recall. Description of Remedy : Description of Remedy Program : • The remedy involves installing updated software with the blink code function disabled so it does not interfere with ABS fault logic command for ABS lamp. • 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 updated software for the remedy disables the blink code command that interfered with the ABS lamp command in the recalled population. The recalled population contains the blink code command that interferes with the ABS lamp command. Identify How/When Recall Condition was Corrected in Production : 05/15/2023 – Navistar production began use of updated software and/or installation of ECU’s with updated software. Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 07/24/2023. Planned Dealer Notification Date : JUL 24, 2023 – JUL 24, 2023 Planned Owner Notification Date : JUL 24, 2023 – JUL 24, 2023 * NR – Not Reported

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