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June 2, 2023 NHTSA CAMPAIGN NUMBER: 23V397000
Brake Pressure Switch May Short and Cause Fire
An electrical short in the brake pressure switch can overheat the circuit and increase the risk of a fire while driving or parked.
NHTSA Campaign Number: 23V397
Manufacturer Navistar, Inc.
Components SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected 6,786
Summary
Navistar, Inc. (Navistar
) is recalling certain 2016 International
DuraStar, 2018-2020 and 2023-2024 International
1300FBC Stripped chassis, 2019-2022 IC Bus CE Commercial bus, 2019-2024 IC Bus TC Commercial bus, and 2019-2024 International
MV vehicles. The brake pressure switch assembly may leak brake fluid
into the brake pressure switch’s electrical components and cause an electrical short-circuit.
Remedy
Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will replace the brake pressure switch and if necessary, the wire harness or fuse, free of charge. Owner notification letters are expected to be mailed August 1, 2023. Owners may contact Navistar’s customer service at 1-800-448-7825. Navistar
’s number for this recall is 23517.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Navistar 23517 Chronology of Events
- 09/27/2022 Navistar
receives communication from General Motors
(GM) of a vehicle fire on a 2019 Chevrolet
Silverado Medium Duty vehicle and that they have initiated an investigation.
- 10/10/2022 Navistar
reviews warranty claim data for International
CV vehicles for emergency brake booster pump running with ignition key off. There were 115 claims processed 05/29/2019 through 06/30/2022. There are no claims for fire or other thermal events found at this time.
- 10/20/2022 Navistar
and GM meet to review a list of six suspect GM vehicles that had a thermal event and review vehicle build configuration for clues as to the potential cause.
- 12/15/2022 Initial testing determined that simulating a brake switch that failed in the closed position will cause the brake assist motor to run continuously, however after 1.5 hours of running, there was no detectable increase in temperature of the wiring.
- 12/16/2022 Navistar
Supplier Recovery independently working to reduce switch warranty, receives data from pressure switch supplier (Kodiak) showing sealant cracks and delamination contributing to high warranty return rates.
- 01/31/2023 Navistar
and GM review parts received from a GM vehicle suspected of a thermal event. Inspection of the switch yielded a low resistance short between the terminals, allowing the pump to run continuously.
- 02/13/2023 During an x-ray analysis, various parts of the switch, connector and wires were cut apart and examined. An unknown residue was found inside of the wiring. This was then sent to a lab to perform chemical analysis on the residue.
- 03/03/2023 Received lab results showing residue in wire is brake fluid
.
- 03/17/2023 Navistar
receives test data from supplier stating that returned switches start allowing brake fluid
to leak internally at a pressure of 25 psi.
- 03/24/2023 Navistar
and pressure switch supplier work on design requirements eliminating the sealer application from pressure switch.
- 04/04/2023 Navistar
Compliance and Engineering meet to investigate the use of the suspect pressure switch and its impact to all vehicle models that use it.
- 04/12/2023 Navistar
Compliance and Engineering finalize the suspect population.
- 04/13/2023 Navistar
declares a Safety Recall for its CV series trucks.
- 04/14 through 04/21/2023 Navistar
Engineering reviews brake pressure switch harness design differences between the CV and MV series trucks and CE series buses.
- 04/28/2023 Navistar
locates a CE series bus and makes arrangements to perform inspection.
- 05/03/2023 Navistar
performs inspection on CE series bus and finds brake fluid
present in the brake pressure switch connector and in the fuse holder.
- 05/10/2023 Navistar
receives communication from the supplier related to design difference of the MV series truck and CE series bus and a splice in the power circuit of the harness. While the splice blocks capillary action, brake fluid
can still pass through the splice and heat shrink tubing.
- 05/10/2023 through 05/19/2023 Navistar
reviews all other models with hydraulic brakes, both current and previous designs and identifies three other models that are built with the same brake pressure switch and a similar harness design.
- 05/22/2023 Navistar
quarantines MV series trucks and CE series buses at the plants and finalizes the suspect population.
- 05/25/2023 Navistar
declares a safety recall.
22 Affected Products
Vehicles
MAKE | MODEL | YEAR |
IC BUS | CE | 2019-2022 |
IC BUS | TC | 2019-2024 |
INTERNATIONAL![]() | 1300FBC | 2018-2020, 2023-2024 |
INTERNATIONAL![]() | DURASTAR | 2016 |
INTERNATIONAL![]() | MV | 2019-2024 |
3 Associated Documents
Recall Acknowledgement
RCAK-23V397-7007.pdf 646.073KB
Defect Notice 573 Report
RCLRPT-23V397-1078.PDF 218.474KB
Navistar – 23517 Chronology – June 2023
RMISC-23V397-3086.pdf 43.235KB
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SEOCONTENT-START
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-397 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Navistar, Inc. Submission Date : JUN 02, 2023 NHTSA Recall No. : 23V-397 Manufacturer Recall No. : 23517 Manufacturer Information : Manufacturer Name : Navistar, Inc. Address : 2701 Navistar Drive Lisle IL 60532 Company phone : 331-332-1590 Population : Number of potentially involved : 6,786 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2020 International 1300FBC Stripped chassis 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are 317 2018 to 2020 FBC1300 stripped chassis in the suspect population. Production Dates : NOV 29, 2017 – AUG 09, 2019 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-397 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2023-2024 International
1300FBC Stripped chassis 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are 452 2023 to 2024 FBC1300 stripped chassis in the suspect population. Production Dates : MAR 04, 2022 – MAY 19, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2016-2016 International
DuraStar 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are two (2) DuraStar model trucks in the suspect population. Production Dates : JAN 07, 2015 – JAN 29, 2015 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-397 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2019-2024 International
MV 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are 4,192 MV series trucks in the suspect population. Production Dates : OCT 24, 2017 – MAY 19, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2019-2022 IC Bus CE Commercial 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are six (6) CE commercial buses in the suspect population. Production Dates : NOV 26, 2018 – JAN 05, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-397 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 6 : 2019-2024 IC Bus TC Commercial 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 04100 (Brake system, hydraulic [WABCO] Split System). • The inclusive dates of manufacture were determined by when feature code 04100 went into production through the date the issue was contained in manufacturing. • The vehicles in the suspect population were built with feature code 04100 and all similar vehicles not subject to this recall were not built with feature code 04100. There are 335 TC commercial buses in the suspect population. Production Dates : MAY 24, 2018 – MAY 15, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : These vehicles may have been built with a brake pressure switch assembly that allows brake fluid
to leak beyond the diaphragm seal into the pressure switch. The brake fluid
may seep into the switch’s electrical components and short the brake pressure switch and the associated fuse. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If brake fluid
shorts the brake pressure switch and the associated fuse, the circuit can generate excessive heat that can result in a fire that may result in property damage or personal injury to the operator. Description of the Cause : A zinc nickel plating and sealant used to inhibit corrosion within the pressure switch assembly may cause delamination of the sealant which results in small fragments of sealer underneath the diaphragm during assembly which allows brake fluid
to slowly seep past the seal. Identification of Any Warning that can Occur : This condition may set a “service brake system” malfunction indicator lamp. Until the recall remedy is performed, affected owners are advised to park their vehicles outdoors. Involved Components : Part 573 Safety Recall Report 23V-397 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Switch, park brake, HPB system Component Description : Brake pressure switch assembly Component Part Number : 4052584C1 or 4166720C1 Supplier Identification : Component Manufacturer Name : Kodiak Controls (Kodiak) Address : 734 Oakridge Dr. Romeoville Illinois 60446 Country : United States Chronology : The Chronology exceeds the 2000 character limit and will be submitted as a miscellaneous supporting document Description of Remedy : Description of Remedy Program : • The remedy will involve replacing the brake pressure switch assembly and any wire harness found with brake fluid
at the brake pressure switch connector or the associated fuse. • 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 brake pressure switch assembly is built without the corrosion inhibitor sealant where the recalled brake pressure switch assembly was built with the corrosion inhibitor sealant. Identify How/When Recall Condition was Corrected in Production : 05/22/2023 – Navistar Manufacturing began use of a redesigned brake pressure switch assembly (without the corrosion inhibitor sealant). Recall Schedule : Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be mailed by 08/01/2023. Planned Dealer Notification Date : AUG 01, 2023 – AUG 01, 2023 Planned Owner Notification Date : AUG 01, 2023 – AUG 01, 2023 Part 573 Safety Recall Report 23V-397 Page 6 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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