2002 International Prostar TSBs
135 Technical Service Bulletins across 15 categories
Categories
Other
34 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
J1939 Data link source address information
PicoScope Test One Channel RCT
PicoScope Test Resistance and Ohmmeter
PicoScope Test for Datalink (CAN) Health Shorts & opens
Driveline Information Center and Troubleshooting Procedures
Cleaning and Disinfecting Trucks and Buses
J1939 Data Link Troubleshooting
How To Get A Helios Capture; only 1939 and 1708 multiplexed buses and trucks
J1939 Data Link Source Address Information
Driveline Information Center and Troubleshooting Procedures
Hendrickson Assembly Instructions; Transverse Torque Rods
To Get A Helios Capture; All 1939 and 1708 multiplexed trucks only
J1939 Data Link Troubleshooting; Only Models with 250k Baud Data Link (Black 9 Pin Diagnostic Connector)
J1939 Data Link Troubleshooting
NEW Ultrasonic DEF Tank Sending Unit; only models with SCR Aftertreatment system.
J1939 Data Link Troubleshooting
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
OnCommand EZTech
OnCommand EZ-Tech Download Center
Cluster Issues
1939 Data Link Troubleshooting
ESPAR AirTronic Low Run Time.
RADIATOR INTERNAL RESTRICTION AND FLUSH PROCEDURE
IKNOW: REPAIR PROCEDURES FOR COMPLAINTS OF FOUL ODORS IN THE CAB.
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APPLIES TO POST 2010 PROSTAR/TRANSTAR. *JS
Engine
22 bulletinsEngine 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: Vehicle Programming Information for Engine: Single Box 1998-2004 I6 & V8 Applies To: Single Box 1998-2004 I6 & V8
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.
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
Engine Oil Capacities.
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All International electronic engines 1994 to present and Cummins ISB, ISM, or ISX engines
Oil Capacities; All Electronic International Engines 1994 - Present.
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Cummins ISB, ISM & ISX
Engine Oil Capacities All Electronic International Engines 1994 - Present.
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Cummins ISB, ISM & ISX
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
The fire extinguishers may become clogged or require excessive force to activate.
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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 equipped with Kidde model FC5 and FC10 fire extinguishers identified by International part numbers 1696423C2 and 1696423C3 and installed post production at Navistar?s Truck Sales Processing Center (TSPC).
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.
Front Blower Motor Runs Breifly At Initial Power Up
NAVISTAR: SOME NAVISTAR PROSTAR VEHICLES WITH THE CUMMINS ISX 15L ENGINES INSTALLED WERE BUILT WITH THE FRONT LEFT FRAME...
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CROSSMEMBER BOLT INSTALLED IN THE WRONG DIRECTION. *TA
IKNOW: INFORMATION CONCERNING THE SUSPENSION DUMP FEATURE.
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IT ALLOWS THE DUMPING OF AIR FROM THE SUSPENSION BAGS AND TO SET THE POINT CONTROLLED BY THE SUSPENSION HEIGHT CONTROL VALVE. APPLIES TO: POST 2007 PROSTAR AND NHPV WITH SUSPENSION DUMP 595ACA *JS
IK: REPAIR INFORMATION REGARDING THE MISSING OR LOOSE BOLT ATTACHING HORTON STRATIS ANTI ROTATION BRACKET (ARB) TO ENGINE.
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MODEL PROSTAR, WORKSTAR, LONESTAR. NO YEARS LISTED. *PE UPDATED 6/27/2014 *JS UPDATED 11/7/14. *PE UPDATED 1/30/15. *PE
NAVISTAR: TRUCKS EQUIPPED WITH ELECTRIC FUEL TRANSFER PUMP FOR TWO TANKS, THE FUEL IS BALANCE BETWEEN BOTH TANKS.
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THE ENGINE IS SUPPLIED FUEL DIRECTLY FROM THE DRAW TANK. HPV, NGV AND PROSTAR. *PE UPDATED 2/18/14. *PE UPDATED 8/14/15. *PE
INTERNATIONAL: LOWER FRONT SHOCK MOUNT BENDING ON PROSTAR S MODELS (113) BBC W/ALL ENGINES AND PROSTAR MODELS (122) BBC W/CATERPILLAR C15 ENGINES.
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PROSTAR MODELS WITH CATERPILLAR C15 ENGINES WILL ONLY HAVE THE ISSUE ON THE RIGHT SIDE. NO MODEL YEARS LISTED. *PE UPDATED 4/6/11. *PE
Body & Paint
15 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.
Aftertreatment Clamp Corrosion; Single Can Aftertreatment Systems
Water entry into the cab / Adding Cowl tray seal; models built prior to 11/11/2013
Headlight Condensation or Frost; excludes sealed beam headlights such as on WorkStar, Paystar and 9900i)
Body Controller/ESC Software Updates
City Horn Blows When Driver Shuts off Truck and Walks Away; only equipped with with ESC or Body Controller
The First Check to make when Troubleshooting any Body Controller or ESC Issue
Headlight Condensation or Frost; excludes sealed beam headlights such as on WorkStar, Paystar and 9900i)
Windows Stop Randomly or are Inoperative, Power Door Locks are inoperative
Wind noise at upper side door
WIND NOISE AT UPPER SIDE DOOR
COWL TRAY SEAL; ONLY BUILT PRIOR TO 11/11/2013
IKNOW: INSTALL KIT IN ORDER TO ALLEVIATE LOOSE, VIBRATING, OR RATTLING OF THE HOOD-MOUNTED MIRRORS.
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*JS
IKNOW: SLEEPER SIDE SILL/UNDERBODY CROSS-MEMBER WELD CHECK AND REPAIR.
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THE WELDS DESCRIBED HEREIN ARE NEITHER DURABILITY NOR SAFETY CRITICAL WELDS. *JS
INTERNATIONAL: FIXED VENT WINDOW 016HKR REPLACEMENT AND REBONDING INSTRUCTIONS.
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UNWANTED AIR, NOISE, OR WATER INTRUSTION. MODEL YEARS NOT LISTED. *PE
Electrical
14 bulletinsThis article equips technicians with the knowledge and steps needed to efficiently replace and program N9/N10 and N13...
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modules, while addressing potential baud rate incompatibility issues between the replacement module and the vehicle.
This document provides: Steps to take when switch pack programming fails, or when switch pack disappears after body...
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control module update Sample scenarios Additional information to assist readers in understanding DLB switch pack programming
PicoScope Test - Battery Loss of Charge - Parasitic Draw Test
PicoScope Test 5V & 12V Intermittent Open and Short circuit diagnostics
General wheel speed sensor troubleshooting
Tool Instruction - BCM Programming Harness
HVAC fault 2609-19 with 4th Gen BCM; Only models equipped with 4th generation BCM
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
INTERNATIONAL: THERE ARE CODE FAULTS, CAUSED BY LOAD SHEDDING, LOADED IN OTHER MODULES AND UNIT GOES INTO LOAD SHED AND...
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FAILS TO HAVE POWER IN SWITCHES. MODEL PROSTAR, LONESTAR. NO YEARS LISTED. *PE
IKNOW: THE BATTERY CUBE FUSE STUD TERMINAL WITH THE ALTERNATIVE PART NEEDS TO BE REPLACED.
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SOME VEHICLES MAY EXPERIENCE A SHORTED FUSE BECAUSE THE INSTALLATION WAS IMPROPER. MODELS INCLUDE ALL PROSTARS (PRIOR TO SCR RELEASE) *JS
INTERNATIONAL: SPRING HANGER SHACKLE BOLT MAY HAVE BATTERY CABLES ROUTED TOO CLOSE FOR LEFT SIDED BATTERY BOX OR 8600...
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LSM BOC BATTERY BOX FOR EXCOBEDO BUILT PROSTAR 113. NO MODEL YEARS LISTED. *PE
INTERNATIONAL: BATTERY CABLES ROUTED TOO CLOSE TO SPRING HANGER SHACKLE BOLT FOR LEFT-SIDED BATTERY BOX OR 8600 BOC BATTERY BOX.
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MODEL PRO-STAR113 GARLAND BUILT. NO MODEL YEARS LISTED. *PE
INCORRECT 5AMP FUSE AT LOCATION F11-D ON WABCO 6 SENSOR 6 MODULATER.
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*KB
NAVISTAR: HVAC FRONT INSIDE MODULE DRAIN REPAIR.
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*KB
Brakes
6 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.
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
IKNOW: PROSTAR BRAKE ASSEMBLY CONVERSION.
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THE WELD MAY BE CRACKING IN THE STAMPED S-CAM TUBE BRACKET. THE STAMPED SPIDER BRAKE ASSEMBLY SHOULD BE CONVERTED TO A CAST SPIDER BRAKE ASSEMBLY. *JS
NAVISTAR: THE BRAKE LIGHTS STAY ON AND ARE NOT WORKING.
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THERE ARE PROBLEMS WITH VOLTAGE. *RM UPDATED 10/15/12. *PE UPDATED 11/6/2013 *JS
INTERNATIONAL: BRAKE PEDAL NOT RETURNING AND STICKING SLIGHTLY IN THE APPLIED POSITION.
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BRAKE PEDAL NOT RETURNING AND BINDING. BRAKE LIGHT STAYING ON. MODEL PROSTAR, NO MODEL YEARS LISTED. *PE UPDATE 02/17/10. *PE UPDATED 7/16/10. *PE
INTERNATIONAL: ICON WILL NOT FUNCTION PROPERLY.
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ABS LIGHTS COME ON WHEN ICON STARTS OR STOPS. UNIT SHUTS DOWN BEFORE ICON PARAMETER IS REACHED. IF YOU HAVE MORE THAN ONE HOUR IN TROUBLESHOOTING AND DO NOT HAVE A GOOD DIRECTION TO FOLLOW FOR RESOLUTION, PLEASE OPEN A IKNOW CASE FILE. NO MODEL YEARS LISTED. *PE
HVAC & Climate
6 bulletinsTitle: A/C Refrigerant and Oil Capacities Applies To: All current models
A/C Refrigerant and Oil Capacities
A/C Refrigerant and Oil Capacities
A/C Refrigerant and Oil Capacities
NAVISTAR: TROUBLESHOOTING FOR INTERMITTENT OR NO FRONT BLOWER OPERATION.
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*RM
INTERNATIONAL TRUCK: INTERMITTENT OR NO FRONT BLOWER OPERATION.
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OUTLINES THE PROCESS FOR TROUBLESHOOTING THE FRONT BLOWER ON PROSTAR, LONESTAR, DURASTAR, TRANSTAR, AND WORKSTAR MODELS. NO MODEL YEARS LISTED. *PE
Transmission
6 bulletinsTitle: Steering Gear Seal Repair Guidelines Applies To: Steering gears
Power Steering Diagnostics Flow / Pressure Specifications For Power Steering Gears and Power Steering Pumps
Tech Tip to aid technicians in the efficient removal and installation of a TC10 transmission
Transmission Keeps Shifting and Display Keeps Flashing After Ignition is Turned Off; only with Freedom Line Transmission
Eaton Clutch Information
NAVISTAR: STEERING WHEEL WILL NOT HAVE SHIFT CONTROLS DUE TO PHOENIX SHIFTER BEING PROGRAMMED TO LOOK FOR STEERING...
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WHEEL MOUNTED SHIFT CONTROLS AND IF AN ERROR IS DETECTED, A FAULT WILL BE SET. MODEL PROSTAR. *PE UPDATED 9/14/15 *CN
Steering
6 bulletinsAdjustment Procedure for Tilt Only Steering Column; only models with Feature code 0005708
Steering Fluids
Steering Shake, Shimmy, Shudder, or Steering Vibration; only with 14k front weight rated axles and below
INTERNATIONAL: INFORMATION BEING PROVIDED REGARDING THE RUSTING OF POWER STEERING HOSES THAT NEEDS TO BE REMOVED AND REPLACED.
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MODEL PROSTAR. NO MODEL YEARS LISTED. *PE
NAVISTAR: POWER STEERING INTERMEDIATE SHAFT U JOINT END PLAY MEASUREMENT.
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*PE
NAVISTAR: PROSTAR POWER STEERING COOLER HOSES.
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*PE
Lighting
5 bulletinsRepair Procedures for Vehicles Struck by Lightning
Trailer Auxiliary Switch Lamp Burning Out; Only Vehicles Equipped with Feature Code 0008TTH or 0008THG
INTERNATIONAL: WELDON TAIL LIGHTS ARE REPLACING THE TRUCK LITE ON SOME TRUCKS BUILT BEFORE 2/21/13.
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MODEL PROSTAR. NO MODEL YEARS LISTED. *PE UPDATED 07/23/2013 *JS UPDATED 09/11/2013 *JS
IKNOW: REPLACING TRUCK -LITE TAIL LIGHTS WITH WELDON TAIL LIGHTS.
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IF CHANGING FROM TRUCK-LITE TO WELDON FOR THE FIRST TIME ON A VEHICLE, TWO RETROFIT CONVERSION KITS SHOULD BE ORDERED. *JS
NAVISTAR: MAXXFORCE 11, 13, AND 15 RECALIBRATION TO ADRESS FREQUENT WARNING LIGHTS.
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*KB
Fuel System
5 bulletinsLT / ProStar Fuel Tank Unable to Fill; only sleeper models
Dual Fuel Tank Transfer Pump System With Two Wire Pump Troubleshooting; equipped with feature 595192 built after...
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08/19/2002
IK1500051 - DAVCO FUEL PRO 382 TECHNICAL MANUAL, INSTALLATION, DIAGNOSTICS, AND SERVICE
INTERNATIONAL: INFORMATION REGARDING THE FUEL SYSTEM COMPONENTS AND REPAIRS TO CORRECT INTERFERENCE TO AVOID FUEL LINE CONTACT WEAR.
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MODEL PROSTAR. NO MODEL YEARS LISTED. *PE
INTERNATIONAL: THREE INCH FUEL TANK FILL CAP GASKET CRACKING.
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APPLIES TO HEAVY DUTY MODELS. SOME OF THE THREE INCH FUEL FILL CAP GASKETS HAVE BEEN CRACKING. USED PRIMARILY ON HEAVY DUTY VEHICLES LIKE 5000, 8000, 9000 AND PROSTAR. *PE UPDATED 3/20/14. *PE
Software & Calibration
5 bulletinsCluster Software Update Instructions
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
INTERNATIONAL: ON THE AFTERTREATMENT SUPPORT HANGER, THE HORIZONTAL AFTERTREATMENT SUPPORT ROD BOLT IS LOOSE OR...
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BACKED OUT, DUE TO POSSIBLE WEAR AND NEEDS TO BE REPLACED, IF NECESSARY. *PE UPDATED 02/07/2014 *JS
Suspension
4 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
IKNOW: STRATIS FAN HUB DIAGNOSTICS.
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HORTON 12 THX VMASTER ULTRA (STRATIS) VISCOUS FAN DRIVE TROUBLESHOOTING GUIDE. *JS UPDATED 12/16/13. *PE
Infotainment
3 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.
Driver Information Display (VIS/DID) screen fails to boot up.
Radio Diagnostics and Information
Pre-Delivery & Maintenance
2 bulletinsTitle: Service Portal iKNow Feedback Case Types Applies To: All
NAVISTAR: MISLOCATED TORQUE ROD BRACKET ON CERTAIN PROSTAR AND 9000 MODELS.
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REQUIRES AN INSPECTION TO DETERMINE IF THE TORQUE ROD BRACKET WAS MISLOCATED ON DANA 40K AND 46K TANDEM AXLES. MODEL YEARS UNKNOWN. *PE
Tires & Wheels
2 bulletinsSuggested alignment target values when performing a vehicle axle alignment.
Suggested alignment target values when performing a vehicle axle alignment