2002 INTERNATIONAL PROSTAR

1 recalls, 0 complaints - 152 TSBs

ELECTRICAL SYSTEM

Defect Description

NAVISTAR IS RECALLING 51,588 HEAVY TRUCKS, COMMERCIAL BUSES AND SCHOOL BUSES MANUFACTURED BETWEEN NOVEMBER 21, 2000 AND MAY 21, 2008, EQUIPPED WITH ONE OR MORE REMOTE POWER MODULES. THE POTTING MATERIAL THAT ENCAPSULATES THE CIRCUIT BOARD OF THE VEHICLE'S REMOTE POWER MODULE MAY NOT SUFFICIENTLY SE... Read more

Consequence

A FIRE COULD CAUSE PERSONAL INJURY OR DEATH.

Remedy

NAVISTAR WILL NOTIFY OWNERS AND REPAIR THE VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON JULY 10, 2008. OWNERS MAY CONTACT NAVISTAR AT 1-280-461-1890.

51,588 vehicles affected

Manufacturer: NAVISTAR, INC

No complaints found for this vehicle.

Technical Service Bulletins, 2002 INTERNATIONAL PROSTAR

152 manufacturer communications from 94 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
110000 ELECTRICAL SYSTEM	22
118000 ELECTRICAL SYSTEM:SOFTWARE	11
060000 ENGINE AND ENGINE COOLING	10
350000 EQUIPMENT	9
060000 ENGINE (PWS)	8
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL	7
010000 STEERING	5
020000 SUSPENSION	5

010000 STEERING

Suggested alignment target values when performing a vehicle axle alignment.

020000 SUSPENSION

Suggested alignment target values when performing a vehicle axle alignment.

060000 ENGINE AND ENGINE COOLING

Starter Diagnostics and warranty claim procedure; all engines EXCLUDING Cummins ISB engine with Allison transmission or PSI engine.

110000 ELECTRICAL SYSTEM

Starter Diagnostics and warranty claim procedure; all engines EXCLUDING Cummins ISB engine with Allison transmission or PSI engine.

060000 ENGINE AND ENGINE COOLING

Starter diagnostics and warranty claim procedure for all engines and all chassis EXCLUDING vehicles equipped with PSI engines or Cummins ISB engine with Allison transmissions

110000 ELECTRICAL SYSTEM

Starter diagnostics and warranty claim procedure for all engines and all chassis EXCLUDING vehicles equipped with PSI engines or Cummins ISB engine with Allison transmissions

110000 ELECTRICAL SYSTEM

J1939 Data link source address information

110000 ELECTRICAL SYSTEM

PicoScope Test for Datalink (CAN) Health Shorts & opens

110000 ELECTRICAL SYSTEM

PicoScope Test Resistance and Ohmmeter

110000 ELECTRICAL SYSTEM

PicoScope Test - Battery Loss of Charge - Parasitic Draw Test

060000 ENGINE AND ENGINE COOLING

PicoScope Test One Channel RCT

110000 ELECTRICAL SYSTEM

PicoScope Test 5V & 12V Intermittent Open and Short circuit diagnostics

010000 STEERING

Power Steering Diagnostics Flow / Pressure Specifications For Power Steering Gears and Power Steering Pumps

060000 ENGINE AND ENGINE COOLING

Engine Oil Capacities. All International electronic engines 1994 to present and Cummins ISB, ISM, or ISX engines

356000 EQUIPMENT ADAPTIVE/MOBILITY

Engine Oil Capacities. All International electronic engines 1994 to present and Cummins ISB, ISM, or ISX engines

030000 SERVICE BRAKES, HYDRAULIC

General wheel speed sensor troubleshooting

040000 SERVICE BRAKES, AIR

General wheel speed sensor troubleshooting

060000 ENGINE AND ENGINE COOLING

Aftertreatment Clamp Corrosion; Single Can Aftertreatment Systems

020000 SUSPENSION

Suggested alignment target values when performing a vehicle axle alignment

350000 EQUIPMENT

Driveline Information Center and Troubleshooting Procedures

060000 ENGINE (PWS)

Driveline Information Center and Troubleshooting Procedures

100000 POWER TRAIN

Repair Procedures for Vehicles Struck by Lightning

110000 ELECTRICAL SYSTEM

Repair Procedures for Vehicles Struck by Lightning

060000 ENGINE (PWS)

Repair Procedures for Vehicles Struck by Lightning

061500 ENGINE AND ENGINE COOLING:ENGINE:OIL/LUBRICATION

A/C Refrigerant and Oil Capacities

150000 SEAT BELTS

Cleaning and Disinfecting Trucks and Buses

170000 LATCHES/LOCKS/LINKAGES

Cleaning and Disinfecting Trucks and Buses

220000 SEATS

Cleaning and Disinfecting Trucks and Buses

350000 EQUIPMENT

Cleaning and Disinfecting Trucks and Buses

980000 UNKNOWN OR OTHER

Cleaning and Disinfecting Trucks and Buses

110000 ELECTRICAL SYSTEM

J1939 Data Link Troubleshooting

030000 SERVICE BRAKES, HYDRAULIC

Bendix EC80 Blank Module Replacement Program; This document will guide the user through selecting the correct ABS module when it has been determined a replacement is needed. Only Models with EC-80 ABS Controller

110000 ELECTRICAL SYSTEM

Driver Information Display (VIS/DID) screen fails to boot up.

350000 EQUIPMENT

Driver Information Display (VIS/DID) screen fails to boot up.

080000 FUEL SYSTEM, DIESEL

LT / ProStar Fuel Tank Unable to Fill; only sleeper models

060000 ENGINE AND ENGINE COOLING

Oil Capacities; All Electronic International Engines 1994 - Present. Cummins ISB, ISM & ISX

020000 SUSPENSION

Suspension Lean Diagnostics; All models

110000 ELECTRICAL SYSTEM

J1939 Data Link Source Address Information

350000 EQUIPMENT

Hendrickson Assembly Instructions; Transverse Torque Rods

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Hendrickson Assembly Instructions; Transverse Torque Rods

105000 POWER TRAIN:DRIVELINE

Driveline Information Center and Troubleshooting Procedures

350000 EQUIPMENT

Driveline Information Center and Troubleshooting Procedures

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Driveline Information Center and Troubleshooting Procedures

020000 SUSPENSION

Improved Bushings for Hendrickson Torque Rods

110000 ELECTRICAL SYSTEM

Tool Instruction - BCM Programming Harness

350000 EQUIPMENT

Tool Instruction - BCM Programming Harness

060000 ENGINE (PWS)

Engine Oil Capacities All Electronic International Engines 1994 - Present. Cummins ISB, ISM & ISX

353400 EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC.

Radio Diagnostics and Information

060000 ENGINE (PWS)

A/C Refrigerant and Oil Capacities

350000 EQUIPMENT

The fire extinguishers may become clogged or require excessive force to activate. In certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. Only equ

118000 ELECTRICAL SYSTEM:SOFTWARE

Updating OnCommand Link with Accelerator

118000 ELECTRICAL SYSTEM:SOFTWARE

J1939 Data Link Troubleshooting

118000 ELECTRICAL SYSTEM:SOFTWARE

ISX, N13, and N9 / N10 Aftertreatment Private Data Link Troubleshooting

060000 ENGINE (PWS)

Winter Front Usage

060000 ENGINE (PWS)

Engine Oil Capacities

118000 ELECTRICAL SYSTEM:SOFTWARE

OnCommand EZ-Tech

118000 ELECTRICAL SYSTEM:SOFTWARE

Using Supplier Software to Check DTCs

110000 ELECTRICAL SYSTEM

Trailer Auxiliary Switch Lamp Burning Out; Only Vehicles Equipped with Feature Code 0008TTH or 0008THG

061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL

NEW Ultrasonic DEF Tank Sending Unit; only models with SCR Aftertreatment system.

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

NEW Ultrasonic DEF Tank Sending Unit; only models with SCR Aftertreatment system.

110000 ELECTRICAL SYSTEM

Urea Quality Sensor (UQS) Supplemental Diagnostic and Service Information; only models with SCR Aftertreatment system and N9, N10, N13, A26 or Cummins ISB, ISL, ISX engines built from January 2016

060000 ENGINE AND ENGINE COOLING

HVAC fault 2609-19 with 4th Gen BCM; Only models equipped with 4th generation BCM

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

A/C Refrigerant and Oil Capacities

118000 ELECTRICAL SYSTEM:SOFTWARE

Dealer EZ-Tech and Diagnostic Software Support Resource Center

118000 ELECTRICAL SYSTEM:SOFTWARE

J1939 Data Link Troubleshooting

070000 FUEL SYSTEM, GASOLINE

CPA Injector Misfire Detection; Only models with 2004 thru 2017 International engines.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

OnCommand EZTech

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Cylinder Performance Analyzer (CPA) Resource Center; Only models with 2004 thru 2017 International engines.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

OnCommand EZ-Tech Download Center

010000 STEERING

Steering Shake, Shimmy, Shudder, or Steering Vibration; only with 14k front weight rated axles and below

010000 STEERING

Steering Fluids

118000 ELECTRICAL SYSTEM:SOFTWARE

J1939 Data Link Troubleshooting

118000 ELECTRICAL SYSTEM:SOFTWARE

J1939 Data Link Source Address Information

062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM

Cooling System Flush Procedure

118000 ELECTRICAL SYSTEM:SOFTWARE

J1939 Data Link Troubleshooting; Only Models with 250k Baud Data Link (Black 9 Pin Diagnostic Connector)

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

To Get A Helios Capture; All 1939 and 1708 multiplexed trucks only

062100 ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

RADIATOR INTERNAL RESTRICTION AND FLUSH PROCEDURE

162300 STRUCTURE:BODY:DOOR

Wind noise at upper side door

100000 POWER TRAIN

Tech Tip to aid technicians in the efficient removal and installation of a TC10 transmission

350000 EQUIPMENT

Tech Tip to aid technicians in the efficient removal and installation of a TC10 transmission

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

IK1500051 - DAVCO FUEL PRO 382 TECHNICAL MANUAL, INSTALLATION, DIAGNOSTICS, AND SERVICE

110000 ELECTRICAL SYSTEM

Windows Stop Randomly or are Inoperative, Power Door Locks are inoperative

133000 VISIBILITY:POWER WINDOW DEVICES AND CONTROLS

Windows Stop Randomly or are Inoperative, Power Door Locks are inoperative

171100 LATCHES/LOCKS/LINKAGES:DOORS:LATCH

Windows Stop Randomly or are Inoperative, Power Door Locks are inoperative

060000 ENGINE AND ENGINE COOLING

Front Blower Motor Runs Breifly At Initial Power Up

030000 BRAKES (PWS)

NAVISTAR: VARIOUS TYPES NAVISTAR VEHICLES WILL BE RECEIVING UPDATES ON THE REAR S CAM TUBE/ BRACKET PARTS. *TA UPDATED 9/10/15 *CN

101000 POWER TRAIN:CLUTCH ASSEMBLY

Eaton Clutch Information

356000 EQUIPMENT ADAPTIVE/MOBILITY

ESPAR AirTronic Low Run Time.

102000 POWER TRAIN:MANUAL TRANSMISSION

NAVISTAR: STEERING WHEEL WILL NOT HAVE SHIFT CONTROLS DUE TO PHOENIX SHIFTER BEING PROGRAMMED TO LOOK FOR STEERING WHEEL MOUNTED SHIFT CONTROLS AND IF AN ERROR IS DETECTED, A FAULT WILL BE SET. MODEL PROSTAR. *PE UPDATED 9/14/15

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

110000 ELECTRICAL SYSTEM

092100 FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP

Dual Fuel Tank Transfer Pump System With Two Wire Pump Troubleshooting; equipped with feature 595192 built after 08/19/2002

071210 FUEL SYSTEM, GASOLINE:STORAGE:AUXILLARY TANK:SELECTOR DEVICES

NAVISTAR: TRUCKS EQUIPPED WITH ELECTRIC FUEL TRANSFER PUMP FOR TWO TANKS, THE FUEL IS BALANCE BETWEEN BOTH TANKS. THE ENGINE IS SUPPLIED FUEL DIRECTLY FROM THE DRAW TANK. HPV, NGV AND PROSTAR. *PE UPDATED 2/18/14. *PE UPDATE

092100 FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP

251000 ELECTRONIC STABILITY CONTROL:AUTOMATIC (ASC)

The First Check to make when Troubleshooting any Body Controller or ESC Issue

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

NAVISTAR: SOME NAVISTAR PROSTAR VEHICLES WITH THE CUMMINS ISX 15L ENGINES INSTALLED WERE BUILT WITH THE FRONT LEFT FRAME CROSSMEMBER BOLT INSTALLED IN THE WRONG DIRECTION. *TA

118000 ELECTRICAL SYSTEM:SOFTWARE

Cluster Software Update Instructions

353000 EQUIPMENT:ELECTRICAL

J1939 Data Link Troubleshooting

062200 ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

IK: REPAIR INFORMATION REGARDING THE MISSING OR LOOSE BOLT ATTACHING HORTON STRATIS ANTI ROTATION BRACKET (ARB) TO ENGINE. MODEL PROSTAR, WORKSTAR, LONESTAR. NO YEARS LISTED. *PE UPDATED 6/27/2014 *JS UPDATED 11/7/14. *PE

160000 STRUCTURE

WIND NOISE AT UPPER SIDE DOOR

Showing 100 of 152 bulletins.

NHTSA Safety Investigations, INTERNATIONAL PROSTAR

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE, Closed , Model Year: 2012

Accelerator Pedal Fails to Return

The Office of Defects Investigations (ODI) opened Preliminary Evaluation (PE15-013) on 2012-2013 model year (MY) Navistar Prostar vehicles for throttle pedals failing to return to the idle position after being depressed.EWR field reports supplied by Navistar describe the non-returning throttle pedal... s as preventing the engine brake from activating and elevated engine speed making it difficult to stop the vehicle.ODI contacted complainants who alleged the accelerator pedal didn?t return to the idle position.Some drivers indicated they were annoyed, while others stated that at idle they were able to keep the vehicle stopped but need to apply more pressure to the brake pedal.Some consumers indicated that the engine speed was so high with a manual transmission that the engine-brake would not work, while other stated they were able to pull the accelerator pedal back from underneath with their foot and bring the engine speed back to normal.In Navistar?s response to an ODI information request letter, they made ODI aware of 24 consumer complaints concerning non-returning pedals, mostly on manual transmission vehicles.There were no crashes, property damage, injuries or fatalities reported.Navistar identified 1,233 warranty clams related to all accelerator pedal issues, with 70.3% of these claims were on manual transmission vehicles.Navistar informed ODI that they became aware of an unauthorized part change to the throttle control unit assembly (manufactured by Williams Controls) from April 2012 to March 2013.This unauthorized change was corrected and all vehicles were being retrofitted with the new/original designed part.The design of the subject vehicle throttle pedal is a solid-state rotary position sensor device, which transfers voltage based on shaft rotation in either direction from a reference angle.Shaft rotation is obtained by the driver stepping on the accelerator pedal or allowing the pedal to return back to closed throttle (CT) position.Navistar has described how the throttle does not return completely to the CT position due to stack up tolerance issues and backlash in the pinion/lever arm gear set.The accelerator pedal sensor stator can move slightly on the mounting bracket if the accelerator pedal is pushed with extra force.On two separate occasions an ODI investigator drove several of the subject vehicles.The vehicles that had a high idle with automatic transmissions were reasonable to stop even at the elevated engine speeds.Due to the architecture of an automatic transmission, the engine speeds never got high enough to demonstrate a safety related defect while being driven by the ODI investigator.However, the manual transmission vehicles showed a propensity to increase engine speeds in excess of 2,300 RPM?s while the vehicle was at rest.This condition occurs when the clutch is depressed the engine can rise to the elevated governed RPM, resulting in difficulty selecting gears while shifting.In the condition of a loaded vehicle going down a long grade, the inability to down shift could cause difficulty in maintaining or reducing vehicle speed with just the service brakes.Navistar recognizes the pedal issue as a safety related defect and is preforming Safety Recall 15V-776.The recall will only address vehicles with the manual transmission.ODI believes the manual transmission population exhibits a failure mechanism that represents a safety defect and the automatic supplied transmissions vehicles are drivable without similar consequence.The remedy involves recalibration of the engine Electronic Control Module (ECM) to eliminate the high idle condition caused by pedal housing tooling chanRead more

PE, Closed , Model Year: 2013

Headlight failures/fires

This investigation was opened based on a consumer complaint alleging a headlight fire on a MY 2013 International Prostar.A fire cause and origin report accompanied the complaint and placed the origin at the headlight assembly but did not confirm the first material ignited.The complainant reported tw... o injuries due to smoke inhalation by the driver and passenger as well as a broken ankle suffered by the passenger when they jumped out of the vehicle.During the investigation, ODI collected and reviewed subject and peer vehicle information related to the alleged defect.ODI selected model year 2012 and 2014 Navistar Prostar vehicles as peer vehicles.ODI sent an Information Request letter to Navistar in order to collect production, complaint, warranty, part sales, and design information.Navistar provided all requested information.A thorough review of available data revealed the only known complaint and injury event was the single complaint submitted to NHTSA.Navistar reported having received 250 warranty claims relative to the alleged defect on the subject vehicle.A detailed review of these claims indicated that single headlights failed sporadically over the life of the truck.No incidents were found to include simultaneous failure of both the left and right headlights.ODI also analyzed data for 39,687 peer MY 2012 and 2014 Prostar vehicles.Navistar used the same search criteria on the peer vehicles as the subject vehicles and identified 439 warranty claims. Again, no fires, injuries or simultaneous failures were identified.No design changes were reported for the headlights on subject vehicles.However, Navistar reported three design changes for the 2014 peer vehicles.One of the changes was to offer LED headlights.Another involved a changed in the headlight assembly supplier as a cost savings initiative, and the third was in response to warranty claims.All designs are interchangeable with the subject vehicles.Change 91885Z was put into vehicle production on November 4, 2013 and improved the headlight connections.The majority of warranty claims received reported the headlight failed as a result of the connection melting.This change was implemented to correct this issue.ODI surveyed five fleets and all reported they did not have repeat headlight failures with the new harness connectors.Navistar assessed the alleged fire reported to ODI.While the fire did originate in the headlight assembly area,Navistar does not believe it was due to the headlight harness or connections.Navistar believes it originated in the marker/turn signal harness or connection, which is also located in the headlight assembly.Pictures in the cause and origin report clearly show the headlight harness intact, which wouldn't be the case if it was the initial material ignited.This correlates with the driver's statement that the headlights weren't on at the time of failure as there would be no current in the headlight harness if the headlights were not illuminated.ODI does not dispute Navistar's assessment of the alleged defect and did not identify a trend of headlight failures or fires.There is redundancy when a single light fails and it is easily identified and remedied.Additionally, the Prostar features software to alert the driver when a headlight goes out and if properly equipped with satellite communication can simultaneously alert fleet management.This investigation is closed as further use of agency resources does not appear warranted.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency reserves the right to take further action if warraRead more

EQ, Closed , Model Year: 2012

Brake S-Cam Tube Bracket Failure

BACKGROUNDIn a letter dated January 15, 2012, Navistar, Inc. (Navistar) notified the NHTSA that it had decided a defect exists in certain Model Year 2012 and 2013 International brand ProStar and TranStar commercial trucks, manufactured from August 1, 2011 through June 12, 2012, and equipped with bra... ke S-Cam tube bracket assemblies.The brake S-Cam tube bracket assembly on the steering axle may exhibit fractures between the wing bracket and the tube steel when mounted.According to Navistars filing, fractures between the wing bracket and the tube steel may result in an inoperative brake on the affected wheel end resulting in an unexpected pull condition during braking application or an unexpected increase in stopping distance.Either result may increase the risk of a vehicle crash.NHTSA assigned recall number 12V-546 to this matter.On May 28, 2013, the Recall Management Division (RMD) opened this Equipment Query Investigation in order to write to the company that supplied Navistar with these brake S-cam tube bracket assemblies, to notify the supplier of this defect, and to ensure thorough safety recalls are conducted where appropriate.An Information Request (IR) letter was sent to Meritor, Inc. (Meritor) on May 31, 2013 requesting: a list of original equipment vehicle manufacturers and after-market customers that purchased the affected brakes; the name, address and phone number of a contact for each customer; the quantity sold; the dates shipped; and, a defect report.MERITOR RESPONSEIn a letter dated June 13, 2013, Meritor responded to the IR letter and reported that based on its review of the data and information on the brake S-cam tube bracket assemblies, it did not believe these brake assemblies contain a safety related defect.Meritor investigated returned components and determined that fractures in the brake S-Cam tube bracket assemblies resulted from vehicle front-end system vibration; and, there were no defects in the design, material or manufacture of the returned components.Accordingly, Meritor stated that it will not file a defect report or conduct a recall of any equipment.However, as requested by RMD, Meritor provided a purchaser list identifying Navistar as the only purchaser of these brake S-Cam tube bracket assemblies. RECALL MANAGEMENT DIVISION ACTION All vehicle and replacement equipment manufacturers have been identified and have either filed a recall report and are conducting a recall, or have provided a response explaining why they do not believe the products they manufactured are defective.Accordingly, this equipment query is closed.Read more

INTERNATIONAL PROSTAR - All Years Overview

Complete safety history for the INTERNATIONAL PROSTAR across all model years (2002, 2022).

131 Total Recalls

54 Total Complaints

3 Investigations

3 Reported Crashes

4 Reported Fires

0 Reported Deaths

INTERNATIONAL PROSTAR - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2022	1	0	View
2019	3	0	View
2018	6	0	View
2017	9	1	View
2016	8	0	View
2015	7	0	View
2014	10	5	View
2013	18	15	View
2012	18	10	View
2011	15	6	View
2010	10	11	View
2009	9	4	View
2008	9	2	View
2007	3	0	View
2006	1	0	View
2005	1	0	View
2004	1	0	View
2003	1	0	View
2002 (current)	1	0

Other INTERNATIONAL Models

Model	Recalls	Complaints
LONESTAR	154	9	View
LT	151	28	View
MV	144	8	View
DURASTAR	98	6	View
HV	95	1	View
HX	95	0	View
RH	85	2	View
WORKSTAR	82	1	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2002 INTERNATIONAL PROSTAR

Technical Service Bulletins, 2002 INTERNATIONAL PROSTAR

Most Affected Components

NHTSA Safety Investigations, INTERNATIONAL PROSTAR

INTERNATIONAL PROSTAR - All Years Overview

INTERNATIONAL PROSTAR - Year by Year

Other INTERNATIONAL Models