2002 International 4200 problems

What is wrong

On certain trucks equipped with v8 engines and air brakes or air operated park brakes, a stand-off bracket was not installed. The bracket supports the copper air compressor discharge tube. Normal vehicle and engine vibration can cause the unsupported copper tube to fail at or near the air compressor connection.

Risk

A failed compressor discharge tube could deplete the air system and may cause the parking brakes to apply. This condition could cause the vehicle to slow down or stop unexpectedly and result in a crash.

Remedy

Dealers will inspect and repair the stand-off bracket as necessary. Owner notification is expected to begin during december 2003. Owners should contact international truck at 1‑800‑448‑7825.

Recall number 03V414000 · Recall details

What is wrong

Certain heavy duty trucks fail to comply with the requirements of federal motor vehicle safety standard no. 121, "air brake systems." the primary and secondary air supply hoses from the foot valve to the primary and secondary air tanks were improperly routed at the tank.

Risk

If the primary air circuit is damaged, the brakes will not apply when the brake pedal is depressed increasing the risk of a crash.

Remedy

Dealers will inspect and repair vehicles. Owner notification will be completed by october 3, 2003. Owners who take their vehicle to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact international at 1‑800‑448‑7825.

Recall number 03V317000 · Recall details

What is wrong

On certain school and transit buses built with bosch zero offset pin slide (zops) hydraulic disc brakes, the zops hydraulic disc brakes may experience calipers sticking in the applied position, which can result in excessive or abnormal heat generation at one or more of the brakes.

Risk

The combination of the following factors may collectively result in an unreasonable risk to motor vehicle safety: potential fire at a wheel end, high incident rates of stuck calipers, and evacuation and containment concerns relating to multiple passengers.

Remedy

International will notify its customers and repair the buses free of charge. The recall began october 29, 2004.

Recall number 03V062000 · Recall details

What is wrong

On certain medium and heavy duty trucks built with driveline parking brake codes 04gar, the parking brake assembly may not hold the vehicle in position when set. Factors contributing to this possibility are as follows: (1) cracked or broken cams; (2) loose or broken anchor bolts; (3) initial shoe diameter not set properly during assembly, which can lead to progressive component damage; (4) bent adjuster levers that cannot function; or (5) automatic adjuster cables that are disconnected.

Risk

If the parking brake does not function properly, the vehicle could roll, without warning, after the parking brake lever has been set, increasing the risk of a crash.

Remedy

Dealers will replace the cam, lever, and bolt. Owner notification began december 30, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact international at 1‑800‑448‑7825.

Recall number 02V260000 · Recall details

What is wrong

On certain school buses and heavy duty trucks built with international vt365 engines and manufactured at international diesel of alabama. The injector driver modules (idm) built for the vt365 engines could have missing vibration damping/retention shells and a missing hot-melt process on the dc/dc boards.

Risk

The missing shells could allow the larger electronic components to become loose and possible break off inside the module during engine operation. Depending on what electrical component comes off, the effect on engine operation could result in rough running, loss of power, no start, or in the most severe case, immediate engine shut down without warning, increasing the risk of a crash.

Remedy

Dealers will replace the idm modules. Owner notification began october 28, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact international at 1‑800‑448‑7825.

Recall number 02V204000 · Recall details

What is wrong

Certain trucks equipped with engine starters (code 08wwn or 08wwp) built by leece-neville. These starters have a defective terminal adapter stud. The stud is used only at the positive battery connection to the starter solenoid. It was designed to be screwed on over the existing stud to increase the stud diameter to accommodate the larger size of the positive battery cable terminal. The adapter stud was weakened when the hole was drilled too deep.

Risk

This could lead to a direct electrical short to the batteries. If the stud breaks off, the positive battery cable could short directly to ground, which can generate heat and sparks causing a fire.

Remedy

Dealers will replace the adapter stud. Owner notification began april 15, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact international at 1‑800‑448‑7825.

Recall number 02V094000 · Recall details

What is wrong

On certain trucks, the cotter pin that goes through the drag link ball stud at the connection to the pitman arm is missing. This pin prevents the castle nut from loosening.

Risk

If the nut loosens and comes completely off the drag link ball stud, the drag link could detach resulting in a loss of steering control.

Remedy

Dealers will inspect the vehicle and install a cotter pin if it is missing. Owner notification began april 15, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact international at 1‑800‑448‑7825.

Recall number 02V095000 · Recall details

This investigation focused on international medium duty trucksand school bus chassis weighing up to 33,000 pounds, equipped with hydraulic brakes and built with the bosch zero offset pin slide (zops)brake system calipers.international used the zops calipers from april 1997 through june 2002.odi was concerned about reports of the brake calipers sticking in the applied position, resulting in excessive heat.as the investigation progressed, odi became aware of wheel end fires, some of which occurred on school buses.during the investigation odi obtained warranty data which was sorted and analyzed by vrtc test engineers and odi to gain an understanding of the magnitude of the problem.after a thorough warranty data analysis, related testing and document reviews, odi met with international, shared the data analysis and shortly afterwards, international agreed to a safety recall.further details are included on pages 2 - 4.

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