2016 International Lonestar TSBs
210 Technical Service Bulletins across 16 categories
Categories
Other
52 bulletinsThis document will guide the user through understanding Prop Shaft Codes and understanding the variations of prop codes.
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(Metric Prop codes start with the number a 4 and Non metric Prop codes start with a 2.)
Title: Driveline Information Center and Troubleshooting Procedures Applies To: All Vehicles
Title: Fan belt replacement guidelines for frayed edges Applies To: All Models
Certain LoneStar may have an intake air filter that does meet quality standards.
J1939 Data Link Source Address Information
Diagnosis of chassis wander complaints.
J1939 Data Link Source Address Information
J1939 Data Link Troubleshooting
J1939 Data link source address information
Pico Scope CCOS (Crankcase Separator Test)
PicoScope Test One Channel RCT
PicoScope Test Resistance and Ohmmeter
PicoScope Test for Datalink (CAN) Health Shorts & opens
J1939 Data Link Source Address Information
J1939 Data Link Troubleshooting
How to obtain As built parameter list
Cab Lean Concern
Driveline Information Center and Troubleshooting Procedures
Cleaning and Disinfecting Trucks and Buses
J1939 Data Link Troubleshooting
J1939 Data Link Source Address Information
SCR Vehicles Setting DEF Quality Faults due to Crossed DEF Tank Coolant Lines or Inverted DEFTHV
J1939 Data Link Troubleshooting; All Models with 250k Baud Data Link (Black 9-Pin Diagnostic Connector).
Only models built with Cummins X15; Fault Code 7125
vibration at highway speeds; only vehicles with low miles
Child Checkmate is not functioning correctly; Only buses with features 47EXC, 47EXD, 47EXE built from 4/18/16 to 5/15/17
Driveline Information Center and Troubleshooting Procedures
Child Checkmate is not functioning correctly; Only buses with features 47EXC, 47EXD, 47EXE built from 4/18/16 to 5/15/17
Hendrickson Assembly Instructions; Transverse Torque Rods
Programing New Key Fobs
vibration at highway speeds
J1939 Data Link Troubleshooting
NEW Ultrasonic DEF Tank Sending Unit; only models with SCR Aftertreatment system.
J1939 Data Link Troubleshooting
SCR Vehicles Setting 3363-16 (FC1713) due to Crossed DEF Tank Coolant Lines or Inverted DEFTHV
Cooling System Flush Procedure
J1939 Data Link Source Address Information
J1939 Data Link Troubleshooting
Updating OnCommand Link with Accelerator
OnCommand EZ-Tech
Winter Front Usage
ISX, N13, and N9 / N10 Aftertreatment Private Data Link Troubleshooting
J1939 Data Link Troubleshooting
Telematic Installation Guidelines; only Units with 500K Data Link
OnCommand EZTech
OnCommand EZ-Tech Download Center
Pressure Transducer (PT) Switch Install
ESPAR D5 Hydronic Diagnostic Guide
Active Faults During Load Shed
PRESSURE TRANSDUCER (PT) SWITCH INSTALL; MODELS BUILT PRIOR TO JANUARY 20, 2015
PRESSURE TRANSDUCER (PT) SWITCH INSTALL; BUILT BEFORE JANUARY 20, 2015)
RADIATOR INTERNAL RESTRICTION AND FLUSH PROCEDURE
Engine
36 bulletinsThis article only applies to Models w/ 0016UZL Built Between 06/23/2014 05/11/2020 OR Models w/ 0016UZL w/ Safety...
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Recall 14516 Completed Reference the appropriate Technician Manual for models outside of this population. Safety Recall 14516 has been issued for units built before June 23, 2014. For LT and 2018+ LoneStar: If there is a complaint of the bunk blower turning off after an auto start event, the BCM needs to be updated to Data Version 323 or higher. The bunk blower turning off was only present in BCM Data Version 309 to Data Version 322 To properly diagnose the system, you must ensure the recall has been performed. Only the "Cold Loop" sealed refrigerant core PN # 2614669C1 is to be replaced when the refrigerant circuit fails. DO NOT REPLACE THE COMPLETE UNIT IF THE A/C IS NOT FUNCTIONING. Complete unit is not Warrantable Refer to the BASIC TROUBLESHOOTING below before replacing any components. This will help you identify which component is at fault or any electrical issues. Refer to PARTS INFORMATION to properly identify the parts that may require replacement The A/C portion of the system is listed below in the parts section. The 16UZL No-Idle HVAC system is designed to disengage when the engine is started, and can be turned on with the key in any position. This battery-powered no-idle HVAC system provides heating and cooling of the sleeper area without use of the vehicle engine. The system is comprised of the no-idle HVAC components located in the sleeper HVAC module, a separate fuel-operated coolant heater mounted under the sleeper, and four additional batteries housed in a second battery box. The no-idle HVAC system shares the air handling assembly and several major components with the truck's standard HVAC system. Most importantly, the shared evaporator core contains refrigerant circuits for both the no idle system and the truck's standard A/C system. With this configuration, some procedures required to service the no idle A/C system will require opening the refrigerant circuit of the truck's standard A/C system. Trucks equipped with the 16UZL No-Idle HVAC system have two separate HVAC systems (Standard Truck A/C and the MaxxPower unit); it is important to identify each clearly, so you are troubleshooting the correct system. Per the Operator's Manual page 10: Run the heater at least once a month during the year (for a minimum of 15 minutes).
This document provides guidance for assessing the feasibility of implementing a customer-requested change to an engine or vehicle parameter/feature.
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Customer requested changes will be approved in accordance with the requirements specified in 40 CFR Part 1037 to ensure continued compliance with greenhouse gas (GHG) regulations.
New CARB Idle Reduction Change Request
Engine replacements for all International engines will need to follow this procedure.
In some geographic areas, ambient temperatures reaching below 15F (-10 C), including high levels of humidity, an...
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operator may experience engine stalling, low performance, and or poor aftertreatment performance. This is caused by condensation accumulating and freezing within the Charge Air Cooler (CAC); affecting air flow into the engine. This article lists all the currently available winter front covers that can be installed on the front grille and bumper to reduce cold air flow to the engine compartment.
Title: Engine Emission Label Replacement, Certificate of Conformance and Clean Idle Sticker Addition Procedure Applies...
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To: All Navistar Powered Trucks Requesting Engine Emission Label Replacement, Certificate of Conformance and/or Clean Idle Sticker, Clean Truck Check
Title: How to Request a Horsepower Quote Applies To: All International and Cummins Electronic engines
Applies To: All Navistar Powered Trucks Requesting Engine Emission Label Replacement, Certificate of Conformance and/or...
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Clean Idle Sticker, Clean Truck Check
Starter Diagnostics and warranty claim procedure; all engines EXCLUDING Cummins ISB engine with Allison transmission or...
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PSI engine.
How to request a horsepower quote; all International and Cummins engines
Cummins Programming guide and fault codes285 & 265; only vehicles built with Cummins B6.7, X15, or L9 engines
Starter diagnostics and warranty claim procedure for all engines and all chassis EXCLUDING vehicles equipped with PSI...
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engines or Cummins ISB engine with Allison transmissions
QLS Emergency ECM Calibration; only models equipped with Cummins B6.7, X15, L9, or International A26 engines
QLS Emergency Calibration; Models equipped with 2016 and newer Cummins B6.7, X15 and L9 engines or International A26...
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engine.
QLS Emergency Calibration; Models with 2016 Cummins ISX, A26 and EPA 2017 and newer Cummins X15, L9, or B6.7 engines
Engine Oil Capacities.
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All International electronic engines 1994 to present and Cummins ISB, ISM, or ISX engines
Snap-On torque wrench requirement for all big bore engine connecting rod bolt(s).
Fuel Filters, Winter Additives, and Blending Fuels for Cummins Engines
Auxiliary Engine Speed Control Cannot Hold Engine Speed When Using Steering Wheel Switches
MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide; Only sleeper cab models with feature code 16UZL
Oil Capacities; All Electronic International Engines 1994 - Present.
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Cummins ISB, ISM & ISX
Cummins X15, B6.7, L9 engine ECM Programming Procedure; only models built prior to June 4, 2018
Engine Emission Label Replacement, Certificate of Conformance and Clean Idle Sticker Addition Procedure
Cummins X15, B6.7, L9 engine ECM Programming Procedure; only models built prior to June 4, 2018
ISB Starting System Diagnostics; Only models built with cummins ISB engines
Engine Oil Capacities All Electronic International Engines 1994 - Present.
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Cummins ISB, ISM & ISX
Engine Emission Label Replacement, Certificate of Conformance and Clean Idle Sticker Addition Procedure; only Navistar...
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Powered Trucks
Urea Quality Sensor (UQS) Supplemental Diagnostic and Service Information; only models with SCR Aftertreatment system...
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and N9, N10, N13, A26 or Cummins ISB, ISL, ISX engines built from January 2016
MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide; models equipped with feature 16UZL
Engine Oil Capacities
CPA Injector Misfire Detection; Only models with 2004 thru 2017 International engines.
Cylinder Performance Analyzer (CPA) Resource Center; Only models with 2004 thru 2017 International engines.
IK2600225 - 500K BAUD ENGINE MODULE PROGRAMMING
IK1201326 - SERVICE PARTS DAMAGED NEW TURBOCHARGER OIL SUPPLY TUBE
PERFORMING RELATIVE COMPRESSION TEST AND MISFIRE TEST WITH CPA TOOL
IK1201253 - EXHAUST MANIFOLD SERVICE PROCEDURES
Electrical
22 bulletinsThis document details the procedure that must be followed to ensure proper alternator troubleshooting.
This document covers battery diagnostics, maintenance and storage requirement.
General Wheel Speed Sensor Troubleshooting
PicoScope Wheel Speed Sensor Test
PicoScope Test - Battery Loss of Charge - Parasitic Draw Test
PicoScope Test 5V & 12V Intermittent Open and Short circuit diagnostics
New or replacement body control Module (BC,BCM) not detected; Gen 4 BCM
General wheel speed sensor troubleshooting
Ambient Air Temperature (AAT) Sensor Faults/Location/Diagnostics
Ambient Air Temperature (AAT) Sensor Faults/Location/Diagnostics
Build to VIN Wiring Harnesses
Build to VIN Wiring Harnesses
Tool Instruction - BCM Programming Harness
Build to VIN Wiring Harnesses; Axle Configuration: 6x4
DM harness inspection; Only with Steering Column feature code 05710
HVAC fault 2609-19 with 4th Gen BCM; Only models equipped with 4th generation BCM
Urea Quality Sensor (UQS) Boot Order
Urea Quality Sensor (UQS) Boot Order
Air Conditioning Electrical Diagnostics
Ambient Air Temperature (AAT) Sensor Faults/Location/Diagnostics
HIGH OR SPIKING VOLTAGE ONLY WITH LEECE-NEVILLE ALTERNATOR USING REMOTE VOLTAGE SENSE
NAVISTAR: VARIOUS TYPES OF VEHICLES INCLUDING LONESTAR, PROSTAR, 8600, AND 7600 VEHICLES WILL NEED AN OPERATION TO IMPROVE THE CAB CIRCUIT GROUNDS.
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7/17/15 *TA
Body & Paint
16 bulletinsThis article addresses chassis lean conditions on all chassis.
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This does not include any diagnostics for body leans such as a cab lean. Keep in mind that a chassis lean may cause or accentuate a cab lean. Filling out the printable form and using the notes in blue will help you to determine the source of the lean and identify the action and parts required to correct the lean.
Cab water leak troubleshooting tips; HX with steel cab only
Cab water leak troubleshooting tips
Aftertreatment Clamp Corrosion; Single Can Aftertreatment Systems
Day cab roof air deflector causing loud vibration noise at highway speed
Day Cab Roof Air Deflector Vibrates against Cab Roof; only models with P/N 4067947C92 Roof Air Deflector
Water Leaks Past Plastic Vapor Barrier Sheet in the Inner Cavity of the Cab Entry Door
Wind noise at upper side of cab door due to door out of alignment
Cab Water Leak Troubleshooting Tips; Excluding 9000i, PayStar(HX), CityStar, or LoadStar
The First Check to make when Troubleshooting any Body Controller or ESC Issue
Headlight Operation and Troubleshooting; only Post 2007 Vehicles Built with a Body Controller
Body Controller Resource Center
Mirror / Map Light / Visor LED Lighting Up when CB MIC is keyed
Mirror / Map Light / Visor LED Lighting Up when CB MIC is Keyed
Wind noise at upper side door
BODY CONTROLLER UPDATES; ONLY WHEN EQUIPPED WITH 500K BAUD COMMUNICATION NETWORK
Brakes
13 bulletinsThis document will guide the user through a step-by-step procedure for detecting water leaks in vehicle cabs and...
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windshields using an ultrasonic sound detector.
This document is to guide users to eliminate brake pedal rattle noise.
Horizon Cab Door Field Replacement and the Side Window Air Deflectors.
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NOTE: This article will only be applicable to cabs with the deflector mounted on the door pillar. If the cab has the deflector at the windshield, this article does not apply.
Bendix EC80 Blank Module Replacement Program; This document will guide the user through selecting the correct ABS module...
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when it has been determined a replacement is needed. Only Models with EC-80 ABS Controller
Brake Lights Staying On
Cab Water Leak Troubleshooting Tips; primarily for Sleeper cab models and some aspects may also apply to all cabs...
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excluding 5000,9000, PayStar, cityStar
A diaphragm in the spring brake chamber may not be seated fully into the pressure plate and may cause internal leakage...
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in the chamber, resulting in the parking brake to not fully release and drag.
Brake Light Operation on HPV, ProStar and LoneStar
Standard to Heavy Duty Brake Chamber Replacement
The air dryer mounting bracket may fracture, which could cause the air dryer to separate from the vehicle frame with...
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possible airline separation from the dryer, resulting in air system leaks or loss of air pressure to the brake system.
Adding an Electronic Trailer Brake Controller
Brake Single Hot Wheel End Service Procedure
NEW BRAKE LIGHT OPERATION; PROSTAR AND LONESTAR WITH AIR BRAKES
HVAC & Climate
11 bulletinsThis document will guide the user through the necessary steps to install the Pressure Transducer (PT) Switch Conversion...
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Kit onto model year 2012 thru 2016 ProStar and LoneStar(Built prior to January 20,2015). This conversion is required to be performed during a A/C system failure in which the refrigerant system is opened.
Title: A/C Refrigerant and Oil Capacities Applies To: All current models
Potential A/C Compressor Parts shortage - 4158126C1 (A/C compressor)
A/C Refrigerant and Oil Capacities
Air Pressure Gauges and A/C Pressure Transducer Troubleshooting
Air Pressure Gauges and A/C Pressure Transducer Troubleshooting
A/C Refrigerant and Oil Capacities
Espar Airtronic Heater Diagnostic Guide; only models with Feature code 16VTV
A/C Refrigerant and Oil Capacities
2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
2010 AND NEWER VEHICLE AIR CONDITIONING DIAGNOSTICS (START HERE)
Infotainment
11 bulletinsThis tool is designed to compare Diamond Logic feature data across multiple vehicle configuration files.
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It allows users to quickly load files either manually or directly from the Diamond Logic Builder Vehicles folder using VIN-based selection. As files are added or removed, the comparison runs automatically with no manual action required. The program presents results in an interactive table that shows feature codes, descriptions, access levels, and whether each feature is present in each selected file. Built-in search, filtering, and sorting make it easy to locate specific features or focus only on differences between files. Column visibility can be customized to show or hide descriptions and access information as needed. Users can remove files individually or clear all files at once, with results updating instantly. The tool also includes reporting and export options that reflect exactly what is visible on screen, allowing results to be printed, copied, saved as text, or exported to CSV for use in Excel or other spreadsheet tools. Overall, the program streamlines the process of comparing vehicle feature configurations, helping users quickly identify differences, validate setups, and document results without manual comparison or external tools.
Radio Diagnostics and Information
Driver Information Display (VIS/DID) screen fails to boot up.
NEW Ultrasonic DEF Head Unit; All SCR vehicles
NEW Ultrasonic DEF Head Unit available; Only models equipped with SCR Aftertreatment.
NEW Ultrasonic DEF Head Unit; Only vehicles Equipped with SCR
NEW Ultrasonic DEF Head Unit; only models equipped with SCR Aftertreatment
NEW Ultrasonic DEF Head Unit
Radio Diagnostics and Information
Information Display won't boot up
RADIO DIAGNOSTICS AND INFORMATION
Steering
11 bulletinsSteering Shake, Shimmy, Shudder, Wobble, Steering Vibration; only models built with 14K weight rated axles or lower
Steering Shake, Shimmy, Shudder, Steering Vibration; Only ProStar / LoneStar and LT / RH with 14k front weight rated...
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axles and below
Steering Shake, Shimmy, Shudder, Steering Vibration.
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Only models with14k front weight rated axles and below
Steering intermittently goes into a shimmy after hitting a bump.
Steering Shake, Shimmy, Shudder, or Steering Vibration; only with 14k front weight rated axles and below
Steering Shake, Shimmy, Shudder, Steering Vibration; only models with 14k front weight rated axles and below
Steering Shake, Shimmy, Shudder, Steering Vibration; only models with 14k front weight rated axles and below
Steering Fluids
Steering Shake, Shimmy, Shudder, or Steering Vibration; only with 14k front weight rated axles and below
The castellated nut and cotter pin that fastens the tie rod end to the steering knuckle may have not been tightened to...
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their specified assembly torque and over time may loosen resulting in looseness in steering; Commercial Vehicles only.
NEW STEERING SHAFT HEX BOLT
Tires & Wheels
9 bulletinsThis article describes how to fix a speedometer that does not read accurately.
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An inaccurate speedometer can be caused by changing the tire size, changing rear axle ratio (RAR), or by parameters being inadvertently changed during a programming event. Use the formulas and calculator below to correct the pulses per mile (PPM).
Suggested alignment target values when performing a vehicle axle alignment.
Cab Components That Reduce Wheel End Vibration Complaints
Cab Components That Reduce Wheel End Vibration Complaints.
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NOTE: Lonestar Day Cab Only
Suggested alignment target values when performing a vehicle axle alignment
Suggested alignment target values when performing a vehicle axle alignment
FLR-10 Bendix Wingman Misalignment Issues; only models with Feature Code 08TKY Wingman FLR-10 Radars
FLR-10 Bendix Wingman Misalignment Issues; only models with Feature Code 08TKY Wingman FLR-10 Radars
Fifth Wheel Jaw Unlock; only models with Feature 595BAW or 597017 - electronic Jaw release
Transmission
7 bulletinsTitle: Steering Gear Seal Repair Guidelines Applies To: Steering gears
Power Steering Diagnostics Flow / Pressure Specifications For Power Steering Gears and Power Steering Pumps
Power Take Off (PTO) Programming on LT, RH and LoneStar Models with the Eaton Endurant Transmission; only models with...
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feature code 13GZD, 13GYY, 13GYZ, 13GZA, 13GZB, or 13GZC
Certain LoneStar models may have been built without transmission oil cooler lines.
Power Take Off (PTO) Programming on Models with the Eaton EndurantTransmission; only with feature codes 13GZD, 13GYY,...
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13GYZ, 13GZA, 13GZB, or 13GZC
Hard to Crank Condition with Hydraulic Clutch Linkage and Solo Clutch
HARD TO CRANK CONDITION ON VEHICLES WITH HYDRAULIC CLUTCH LINKAGE AND SOLO CLUTCH
Hybrid & EV
7 bulletinsXantrex 1200W Power Inverter Information; only models with feature code 0008XLD
Cooper Bussmann Inverter Information/Diagnostics; only models with feature code 0008XDM or 0008XDN and built after...
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05/12/2014
Xantrex 1200W Power Inverter Information; only models with feature code 0008XLD
Cooper Bussmann Inverter Information/Diagnostics; only models with feature code 0008XDM or 0008XDN and built after...
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05/12/2014
Xantrex 1200W Power Inverter Information; only models with feature code 0008XLD
Cooper Bussmann Inverter Information/Diagnostics
Cooper Bussmann Inverter Information/Diagnostics
Software & Calibration
5 bulletinsCluster Software Update Instructions
Controller Updates for 500k Baud; only vehicles with 500k baud data link
Using Supplier Software to Check DTCs
Dealer EZ-Tech and Diagnostic Software Support Resource Center
NAVISTAR: VARIOUS TYPES NAVISTAR VEHICLES WILL BE RECEIVING UPDATES ON THE REAR S CAM TUBE/ BRACKET PARTS.
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*TA UPDATED 9/10/15 *CN
Pre-Delivery & Maintenance
3 bulletinsTitle: Service Portal iKNow Feedback Case Types Applies To: All
Frame Rail Straightness Inspection Procedure
LoneStar Air Filter Service Procedure
Suspension
3 bulletinsThis document reminds technicians of the critical relationship between the truck's suspension and the driveline operating angles.
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The information applies to diesel, gas, and electric vehicles.
Suspension Lean Diagnostics; All models
Improved Bushings for Hendrickson Torque Rods
Lighting
2 bulletinsRepair Procedures for Vehicles Struck by Lightning
Trailer Auxiliary Switch Lamp Burning Out; Only Vehicles Equipped with Feature Code 0008TTH or 0008THG
Fuel System
2 bulletinsAn incomplete weld at the flared section of the tail pipe may cause a crack in the weld, which may result in partial or...
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full separation of the tail pipe from the vertical exhaust pipe.
IK1500051 - DAVCO FUEL PRO 382 TECHNICAL MANUAL, INSTALLATION, DIAGNOSTICS, AND SERVICE