24504 – Steering Gear Assembled Incorrectly – 2024 IC Bus CE School Buses

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-089
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. FEB 14, 2024 NHTSA Recall No. : 24V-089 Manufacturer Recall No. : 24504 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 1,191 Estimated percentage with defect : 2 %
Vehicle Information :
Vehicle 1 : 2024-2024 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 R. H. Sheppard M100P, M110P, HD94P, XD120P, MD83, SD110P, M83P, and M94S model steering
gears.
• The inclusive dates of manufacture were determined by suspect steering gear serial numbers provided by RH Sheppard and production data at Navistar’s vehicle manufacturing plants.
• The vehicles in the suspect population may have been built with steering gears with suspect serial numbers and all other similar vehicles were not.
There are 1,191 CE school buses in the suspect population. Production Dates : JUL 17, 2023 – DEC 14, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : As reported by R. H. Sheppard Co., Inc. in 24E-094, the defect is a steering gear assembled with fewer than the required number of recirculating balls.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : As reported by R. H. Sheppard Co., Inc in 24E-094, a steering gear with fewer than the required number of recirculating balls may bind when loads are applied. In some cases, the balls may align on the same side of the gear’s worm-shaft and concentrated loads may cause the gear’s internal parts to fracture resulting in loss of vehicle steering. Loss of steering increases the
likelihood of a crash. Part 573 Safety Recall Report 24V-089 Page 2 Description of the Cause : As reported by R. H. Sheppard Co., Inc in 24E-094, an error of the steering gear recirculating ball insertion process occurred during assembly. A gap in the rework process allowed for potentially less than the required number of balls to be installed into the gear without detection. Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : Steering gear Component Description : Steering gear Component Part Number : Various Supplier Identification : Component Manufacturer
Name : Bendix Commercial Vehicle Systems LLC Address : 35500 Chester Rd.
Avon Ohio 44011
Country : United States Chronology :
• 12/19/2023 – RH Sheppard notifies Navistar they have submitted a 573 Defect Notice to NHTSA related to their RH Sheppard steering gears and supplied Navistar with a list of 74 specific suspect serial numbers.
• 12/19/2023 thru 01/02/2024 – Navistar quarantines all RH Sheppard equipped vehicles and inventory steering gears at the assembly plants. One suspect gear was found and repaired. Two other suspect steering gears were sold through Navistar’s Parts System and have identified where these two gears were shipped to.
• 01/04/2024 thru 01/30/2024 – Navistar conducts a search of manufacturing records to identify vehicles built with a suspect steering gear serial number.
• 01/31/2024 – Navistar Finalizes the suspect population.
• 02/01/2024 – Navistar declares a Safety Recall. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-089
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The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : • The remedy will involve replacing any steering gear found with a
suspect serial number.
• 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 steering gears were assembled with the correct number of recirculating balls where the recalled steering gears may not have been.
11/27/2023 – As reported by R. H. Sheppard Co. Inc. in 24E-094, the gap in the manufacturing control logic was corrected for the reworked gears. Additional inspection steps are added to confirm that any rework certainly contained the corrected number of recirculating balls. Recall Schedule :
Description of Recall Schedule : It is estimated that the dealer notification letter will be mailed by
03/11/2024 and that the Customer notification letter will be mailed by 03/18/2024.
Planned Dealer Notification Date : MAR 11, 2024 – MAR 11, 2024
Planned Owner Notification Date : MAR 18, 2024 – MAR 18, 2024
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-089
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Navistar, Inc. FEB 08, 2024 NHTSA Recall No. : 24V-089 Manufacturer Recall No. : 24504 Manufacturer Information :
Manufacturer Name : Navistar, Inc.
Address : 2701 Navistar Drive
Lisle IL 60532 Company phone : 331-332-1590
Population :
Number of potentially involved : 1,191 Estimated percentage with defect : 2 %
Vehicle Information :
Vehicle 1 : 2024-2024 IC Bus CESB
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by models equipped with R. H. Sheppard M100P, M110P, HD94P, XD120P, MD83, SD110P, M83P, and M94S model steering
gears.
• The inclusive dates of manufacture were determined by suspect steering gear serial numbers provided by RH Sheppard and production data at Navistar’s vehicle manufacturing plants.
• The vehicles in the suspect population may have been built with steering gears with suspect serial numbers and all other similar vehicles were not.
There are 1,180 CE school buses in the suspect population. Production Dates : JUL 17, 2023 – DEC 14, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-089 Page 2 Vehicle 2 : 2024-2024 IC Bus CE SBus
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL
Descriptive Information : • The suspect population is identified by models equipped with R. H. Sheppard M100P, M110P, HD94P, XD120P, MD83, SD110P, M83P, and M94S model steering
gears.
• The inclusive dates of manufacture were determined by suspect steering gear serial numbers provided by RH Sheppard and production data at Navistar’s vehicle manufacturing plants.
• The vehicles in the suspect population may have been built with steering gears with suspect serial numbers and all other similar vehicles were not.
There are 11 CE SBus school buses in the suspect population.
Production Dates : SEP 21, 2023 – OCT 18, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : As reported by R. H. Sheppard Co., Inc. in 24E-094, the defect is a steering gear assembled with fewer than the required number of recirculating balls.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : As reported by R. H. Sheppard Co., Inc in 24E-094, a steering gear with fewer than the required number of recirculating balls may bind when loads are applied. In some cases, the balls may align on the same side of the gear’s worm-shaft and concentrated loads may cause the gear’s internal parts to fracture resulting in loss of vehicle steering. Loss of steering increases the likelihood of a crash.
Description of the Cause : As reported by R. H. Sheppard Co., Inc in 24E-094, an error of the steering gear recirculating ball insertion process occurred during assembly. A gap in the rework process allowed for potentially less than the required number of balls to be installed into the gear without detection. Identification of Any Warning
that can Occur : None Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-089 Page 3 Component Name 1 : Steering gear Component Description : Steering gear Component Part Number : Various Supplier Identification : Component Manufacturer
Name : Bendix Commercial Vehicle Systems LLC Address : 35500 Chester Rd.
Avon Ohio 44011
Country : United States Chronology :
• 12/19/2023 – RH Sheppard notifies Navistar they have submitted a 573 Defect Notice to NHTSA related to their RH Sheppard steering gears and supplied Navistar with a list of 74 specific suspect serial numbers.
• 12/19/2023 thru 01/02/2024 – Navistar quarantines all RH Sheppard equipped vehicles and inventory steering gears at the assembly plants. One suspect gear was found and repaired. Two other suspect steering gears were sold through Navistar’s Parts System and have identified where these two gears were shipped to.
• 01/04/2024 thru 01/30/2024 – Navistar conducts a search of manufacturing records to identify vehicles built with a suspect steering gear serial number.
• 01/31/2024 – Navistar Finalizes the suspect population.
• 02/01/2024 – Navistar declares a Safety Recall. Description of Remedy :
Description of Remedy Program : • The remedy will involve replacing any steering gear found with a
suspect serial number.
• 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 steering gears were assembled with the correct number of recirculating balls where the recalled steering gears may not have been. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-089
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The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
11/27/2023 – As reported by R. H. Sheppard Co. Inc. in 24E-094, the gap in the manufacturing control logic was corrected for the reworked gears. Additional inspection steps are added to confirm that any rework certainly contained the corrected number of recirculating balls. Recall Schedule :
Description of Recall Schedule : It is estimated that the dealer notification letter will be mailed by
03/11/2024 and that the Customer notification letter will be mailed by 03/18/2024.
Planned Dealer Notification Date : MAR 11, 2024 – MAR 11, 2024
Planned Owner Notification Date : MAR 18, 2024 – MAR 18, 2024
* NR – Not Reported

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