24502 – High Voltage Cables Labeled Incorrectly – 2024 IC BUS EV School Buses

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. JAN 18, 2024 NHTSA Recall No. : 24V-027 Manufacturer Recall No. : 24502 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 20 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2024-2024 IC 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 codes 0008TLC (210 kWh Total Battery Capacity).
• The inclusive dates of manufacture were determined by when high voltage cables with the incorrect identification marking tape were installed through when high voltage cables with the correct identification marking tape were installed.
• The vehicles in the suspect population were built with incorrect identification marking tape on the high voltage positive cables from the battery packs to the manual service disconnects (MSDs) and all similar vehicles outside the suspect population were built with the correct identification marking tape.
There are 20 EV school buses in the suspect population. Production Dates : JUL 20, 2023 – AUG 07, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The high voltage positive cables from the battery packs to the MSDs may have incorrect identification marking tape, blue in color or no tape at all indicating a lower level (2 or 1) of isolation, instead of white in color, indicating a level 3 isolation (battery fuse removal).
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : An incorrectly identified cable may indicate to a first responder, technician, or customer that the cable is deenergized, when it may not be, possibly
increasing the risk of electrical shock that may result in personal injury or Part 573 Safety Recall Report 24V-027 Page 2 death.
Description of the Cause : Certain battery cable kits requiring rework to replace incorrect “blue tape” with correct “white tape” since previous recall (22V-850) may not have been properly reworked. Some kits may still have the “blue tape,” and some may not have any tape at all. Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : Cable; HV Battery Component Description : A3 MSD2 OUT TO SBOX LWB Component Part Number : 4304601C92 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
• 11/15/23 – Navistar Manufacturing reports the issue to Field Quality.
• 11/16/23 to 01/08/2024 – Navistar Manufacturing quarantines all units (248) onsite at the Tulsa Bus Plant. An inspection found 10 units with the incorrect striping tape color.
• 12/1/2023 – Navistar Product Safety was informed that the corrective actions in place for safety recall 22V-850 did not stay in place.
• 12/05/2023 thru 1/8/2024 – Navistar Product Safety works with Manufacturing and Service Engineering reviewing parts at their storage locations, plant assembly records, and operator part shortage reports, looking for trends to determine the potential suspect population.
• 12/6/2023 – Product Safety meets with Service Engineering, to review the results of 14 inventory EV buses inspected at a dealership. Of these, 10 did not have the correct color tape and required repairing.
• 12/13/2023 – Navistar Manufacturing revised the Point of Application (POA) inspection checklist to verify correct color identification tape is present.
• 01/09/2024 – Product safety finalizes the suspect population. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-027
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
• 01/11/2024 – Navistar declares a Safety Recall.
Description of Remedy :
Description of Remedy Program : • The remedy will involve inspecting the high voltage cables for the
presence of the correct “white” identification tape and installing “white” identification tape on cables without identification tape or cables with incorrect identification tape.
• 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 : The remedy will involve installation of “white” high voltage identification tape where the recalled cables have no high voltage identification tape.
12/13/2023 – Navistar Manufacturing revised inspection checklist to verify correct Identification tape is present on the battery high voltage cables to the MSDs. Recall Schedule :
Description of Recall Schedule : It is estimated that the Customer and Dealer notification letters will be
mailed by 03/19/2024.
Planned Dealer Notification Date : MAR 19, 2024 – MAR 19, 2024
Planned Owner Notification Date : MAR 19, 2024 – MAR 19, 2024
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. JAN 24, 2024 NHTSA Recall No. : 24V-027 Manufacturer Recall No. : 24502 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 20 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2024-2024 IC 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 codes 0008TLC (210 kWh Total Battery Capacity).
• The inclusive dates of manufacture were determined by when high voltage cables with the incorrect identification marking tape were installed through when high voltage cables with the correct identification marking tape were installed.
• The vehicles in the suspect population were built with incorrect identification marking tape on the high voltage positive cables from the battery packs to the manual service disconnects (MSDs) and all similar vehicles outside the suspect population were built with the correct identification marking tape.
There are 20 EV school buses in the suspect population. Production Dates : JUL 20, 2023 – AUG 07, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The high voltage positive cables from the battery packs to the MSDs may have incorrect identification marking tape, blue in color or no tape at all indicating a lower level (2 or 1) of isolation, instead of white in color, indicating a level 3 isolation (battery fuse removal).
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : An incorrectly identified cable may indicate to a first responder, technician, or customer that the cable is deenergized, when it may not be, possibly
increasing the risk of electrical shock that may result in personal injury or Part 573 Safety Recall Report 24V-027 Page 2 death.
Description of the Cause : Certain battery cable kits requiring rework to replace incorrect “blue tape” with correct “white tape” since previous recall (22V-850) may not have been properly reworked. Some kits may still have the “blue tape,” and some may not have any tape at all. Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : Cable; HV Battery Component Description : A3 MSD2 OUT TO SBOX LWB Component Part Number : 4304601C92 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
• 11/15/23 – Navistar Manufacturing reports the issue to Field Quality.
• 11/16/23 to 01/08/2024 – Navistar Manufacturing quarantines all units (248) onsite at the Tulsa Bus Plant. An inspection found 10 units with the incorrect striping tape color.
• 12/1/2023 – Navistar Product Safety was informed that the corrective actions in place for safety recall 22V-850 did not stay in place.
• 12/05/2023 thru 1/8/2024 – Navistar Product Safety works with Manufacturing and Service Engineering reviewing parts at their storage locations, plant assembly records, and operator part shortage reports, looking for trends to determine the potential suspect population.
• 12/6/2023 – Product Safety meets with Service Engineering, to review the results of 14 inventory EV buses inspected at a dealership. Of these, 10 did not have the correct color tape and required repairing.
• 12/13/2023 – Navistar Manufacturing revised the Point of Application (POA) inspection checklist to verify correct color identification tape is present.
• 01/09/2024 – Product safety finalizes the suspect population. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-027
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
• 01/11/2024 – Navistar declares a Safety Recall.
Description of Remedy :
Description of Remedy Program : • The remedy will involve inspecting the high voltage cables for the
presence of the correct “white” identification tape and installing “white” identification tape on cables without identification tape or cables with incorrect identification tape.
• 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 : The remedy will involve installation of “white” high voltage identification tape where the recalled cables have no high voltage identification tape.
12/13/2023 – Navistar Manufacturing revised inspection checklist to verify correct Identification tape is present on the battery high voltage cables to the MSDs. Recall Schedule :
Description of Recall Schedule : It is estimated that the Dealer remedy instructions will release on
01/29/2024 and the customer notification will mail on 01/30/2024.
Planned Dealer Notification Date : JAN 29, 2024 – JAN 29, 2024
Planned Owner Notification Date : JAN 30, 2024 – JAN 30, 2024
* NR – Not Reported

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IC Bus, LLC
2701 Navistar Drive Lisle, IL 60532 USA
navistar.com
IMPORTANT SAFETY RECALL 24502 NHTSA RECALL NO. 24V-027
This notice applies to your vehicle identified on the enclosed card.
FEBRUARY 2024
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 2024 CE EV school bus models built 07/20/2023 thru 08/07/2023 with 0008TLC (210 kWh Total Battery Capacity). REASON FOR THIS RECALL
The high voltage positive cables from the battery packs to the MSDs may have incorrect identification marking tape, blue in color or no tape at all indicating a lower level (2 or 1) of isolation, instead of white in color, indicating a level 3 isolation (battery fuse removal).
RISK TO MOTOR VEHICLE SAFETY
An incorrectly identified cable may indicate to a first responder, technician, or customer that the cable is deenergized, when it may not be, possibly increasing the risk of electrical shock that may result in personal injury or death. DEFECT REMEDY
The repair will involve inspecting the high voltage cables for the presence of the correct ìwhiteî identification tape and installing ìwhiteî identification tape on cables without identification tape or cables with incorrect identification tape. Dealers have parts and instructions to repair your vehicle. The repair will be performed free of charge and take approximately 2.5 hours to complete.
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.com or 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 01/18/2023 thru 02/16/2024. 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 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 ASSISTANCE
If 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 Ownerís 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
Mailed On 02/05/2024
Product Safety

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. FEB 05, 2024 NHTSA Recall No. : 24V-027 Manufacturer Recall No. : 24502 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 20 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2024-2024 IC 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 codes 0008TLC (210 kWh Total Battery Capacity).
• The inclusive dates of manufacture were determined by when high voltage cables with the incorrect identification marking tape were installed through when high voltage cables with the correct identification marking tape were installed.
• The vehicles in the suspect population were built with incorrect identification marking tape on the high voltage positive cables from the battery packs to the manual service disconnects (MSDs) and all similar vehicles outside the suspect population were built with the correct identification marking tape.
There are 20 EV school buses in the suspect population. Production Dates : JUL 20, 2023 – AUG 07, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The high voltage positive cables from the battery packs to the MSDs may have incorrect identification marking tape, blue in color or no tape at all indicating a lower level (2 or 1) of isolation, instead of white in color, indicating a level 3 isolation (battery fuse removal).
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : An incorrectly identified cable may indicate to a first responder, technician, or customer that the cable is deenergized, when it may not be, possibly
increasing the risk of electrical shock that may result in personal injury or Part 573 Safety Recall Report 24V-027 Page 2 death.
Description of the Cause : Certain battery cable kits requiring rework to replace incorrect “blue tape” with correct “white tape” since previous recall (22V-850) may not have been properly reworked. Some kits may still have the “blue tape,” and some may not have any tape at all. Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : Cable; HV Battery Component Description : A3 MSD2 OUT TO SBOX LWB Component Part Number : 4304601C92 Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
• 11/15/23 – Navistar Manufacturing reports the issue to Field Quality.
• 11/16/23 to 01/08/2024 – Navistar Manufacturing quarantines all units (248) onsite at the Tulsa Bus Plant. An inspection found 10 units with the incorrect striping tape color.
• 12/1/2023 – Navistar Product Safety was informed that the corrective actions in place for safety recall 22V-850 did not stay in place.
• 12/05/2023 thru 1/8/2024 – Navistar Product Safety works with Manufacturing and Service Engineering reviewing parts at their storage locations, plant assembly records, and operator part shortage reports, looking for trends to determine the potential suspect population.
• 12/6/2023 – Product Safety meets with Service Engineering, to review the results of 14 inventory EV buses inspected at a dealership. Of these, 10 did not have the correct color tape and required repairing.
• 12/13/2023 – Navistar Manufacturing revised the Point of Application (POA) inspection checklist to verify correct color identification tape is present.
• 01/09/2024 – Product safety finalizes the suspect population. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-027
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
• 01/11/2024 – Navistar declares a Safety Recall.
Description of Remedy :
Description of Remedy Program : • The remedy will involve inspecting the high voltage cables for the
presence of the correct “white” identification tape and installing “white” identification tape on cables without identification tape or cables with incorrect identification tape.
• 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 : The remedy will involve installation of “white” high voltage identification tape where the recalled cables have no high voltage identification tape.
12/13/2023 – Navistar Manufacturing revised inspection checklist to verify correct Identification tape is present on the battery high voltage cables to the MSDs. Recall Schedule :
Description of Recall Schedule : It is estimated that the Dealer remedy instructions will release on
01/29/2024 and the customer notification will mail on 02/05/2024.
Planned Dealer Notification Date : JAN 29, 2024 – JAN 29, 2024
Planned Owner Notification Date : FEB 05, 2024 – FEB 05, 2024
* NR – Not Reported

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