International Lonestar recalls

• Brakes#2024655October 31, 2024

  9,683 units affected

  Issue: On certain trucks, poor signal strength could cause the electronic control unit (ECU) to stop working or not to work properly. As a result, some safety systems may not work, including the antilock braking system, automatic traction control, electronic stability control, active cruise control and the collision mitigation system. Safety Risks: Vehicle safety systems that don't work correctly could increase the risk of a crash. Corrective Actions: International Motors will notify owners by mail and advise you to take your truck to a dealership to reprogram the ECU software.

• Lights And Instruments#2023303May 26, 2023

  4,703 units affected

  Issue: On certain vehicles, the warning light for the antilock brake system (ABS) doesn't stay on when there's a problem with the system, and the vehicle is moving. Safety Risk: A driver that is not warned about a problem with the antilock brake system could have an increased risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your vehicle to a dealership to update the brake system electronic control unit software.

• Lights And Instruments#2023293May 18, 2023

  1,764 units affected

  Issue: On certain trucks, the backup lamps could be blocked and may not be visible. As a result, the trucks don't meet the requirements of the Canadian regulations. Note: This recall only affects trucks equipped with a pintle hook lowering bracket and feature code 01WPN, 01 WPS, or 01VAL. Safety Risk: Backup lamps that aren't visible could cause a person not to recognize that the vehicle is backing and increase the risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your truck to a dealership to install new tail stop/turn signal lamps with integrated backup lamps.

• Heater And Defroster#2023212April 6, 2023

  3,134 units affected

  Issue: On certain trucks, a wire terminal for the blower motor circuit breaker in the power distribution module (PDM) could overheat and melt. Safety Risk: Wiring that overheats and melts can create the risk of a fire. Corrective Actions: Navistar will notify owners by mail and instruct you to take your truck to a dealership to replace the blower motor wiring terminal in the PDM. The dealership will also inspect and, if necessary, replace the fuse block.

• Brakes#2023140March 16, 2023

  2 units affected

  Issue: On a small number of trucks, when the parking switch is pulled on the dashboard, the park valve module may stick in the un-parked position. If this happens the parking brake would not apply, and the truck could move suddenly. Note: This recall only affects trucks equipped with a Bendix Intellipark electronic parking brake. Safety Risk: Sudden and unexpected movement of the truck could increase the risk of a crash. Corrective Actions: Navistar will notify owners by mail. The corrective actions for this recall are under development.

• Suspension#2022665November 23, 2022

  1,884 units affected

  Issue: On certain vehicles, the lock nuts for multiple front and rear suspension and steering parts may not have been manufactured correctly. As a result, the nut(s) could loosen. If this happens, there could be a sudden change in vehicle stability and/or a loss of steering control. Safety Risk: A loss of steering could create the risk of a crash. A sudden change in vehicle stability could cause a loss of control and increase the risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your vehicle to a dealership to replace the affected hex flange lock nuts.

• Electrical#2022407July 28, 2022

  1,417 units affected

  Issue: On certain trucks, the battery ground cables that connect to the vehicle frame could overheat. If this happens, the battery post could separate and cause a loss of electrical power. As a result, the engine could shut off suddenly. Safety Risk: Overheated battery ground cables could create a burn risk. A loss of power while driving could increase the risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your truck to a dealership to replace the alternator positive and ground cables. The dealer will also reroute the alternator ground connection from the frame rail to the starter.

• Steering#2022317June 16, 2022

  3,254 units affected

  Issue: On certain trucks and buses, the steering gear may not have been assembled correctly. As a result, the steering gear could break and cause a loss of steering. Safety Risk: A loss of steering control could create the risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your vehicle to a dealership to inspect the serial number on the steering gear, and replace it, if necessary.

• Electrical#2021068February 17, 2021

  5,146 units affected

  Issue: On certain trucks, the ring terminal that attaches the battery ground cable to the frame may break. If this happens, there could be a loss of electrical power and the engine could shut off suddenly. Safety Risk: A loss of power while driving could increase the risk of a crash. Corrective Actions: Navistar will notify owners by mail and instruct you to take your vehicle to a dealer to replace the battery ground cable.

• Powertrain#2018638November 20, 2018

  2,856 units affected

  On certain vehicles equipped with an electronic clutch actuator (ECA), the clutch may have been manufactured improperly and could fail. If this occurs, the broken clutch components could prevent the transmission from disengaging or shifting to neutral. This could result in unintended vehicle movement, even if the parking brake is applied, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will recalibrate the Transmission Control Module (TCM).

• Brakes#2018484September 10, 2018

  198 units affected

  On certain vehicles, the spring-actuated parking brake may have been improperly assembled. This could result in an internal air leak or a complete separation of the parking brake from the service brake chamber, either of which would cause a loss of braking on the affected wheel assembly. This could cause a sudden, unexpected increase in stopping distance, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect and replace affected brake chamber assemblies.

• Engine#2018475September 5, 2018

  3,970 units affected

  On certain trucks built with a Cummins X15 or ISX15 engine equipped with nylon fuel lines and a banjo bolt on the fuel pump, a blockage in the fuel cooling system may cause a fuel line to burst. This could result in a significant fuel leak onto the roadway, which would create a road hazard for other motorists. Additionally, this condition could also cause an engine stall without warning, without the ability to restart the engine. Both of these conditions may increase the risk of a crash causing injury and/or damage to property. Correction: Cummins-authorized dealers will replace the affected nylon line with a steel line.

• Seats And Restraints#2018232May 3, 2018

  2,093 units affected

  On certain vehicles, the seat belt D-ring mounting bolts may break due to a material defect. If this occurs, the seat belt may not properly restrain the seat occupant in a crash, increasing the risk of injury. Correction: Dealers will inspect the driver and passenger D-ring mounting bolts and replace them as necessary.

• Brakes#2017140March 14, 2017

  663 units affected

  On certain vehicles, the air dryer mounting bracket may fracture and cause the air dryer to separate the frame. This could potentially cause the air lines to separate from the dryer resulting in an air system leak or loss of air pressure to the brake system, which would increase stopping distances and increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will replace the air dryer mounting bracket with an updated heavy duty bracket.

• Electrical#2016648December 21, 2016

  62 units affected

  On some vehicles, the metallic battery box cover latch, when unlatched from its anchor, may articulate and potentially contact the battery jump start stud. If the jump start stud's protective cover has fallen off or is not installed, this may result in an electrical short to ground, increasing the risk of a fire causing injury and/or property damage. Correction: Dealers will install a latch stop to prevent the latch from potentially contacting the stud.

• Engine#2016315June 20, 2016

  159 units affected

  On certain vehicles, the Engine Control Module (ECM) may develop an internal electrical short circuit that could blow a fuse in the ECM's electrical supply circuit. This could cause the engine to stall without warning and prevent the vehicle from being restarted. Engine stalling without warning would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing property damage and/or personal injury. Correction: Dealers will replace the ECM.

• Engine#2015546November 18, 2015

  1,466 units affected

  On certain vehicles equipped with Navistar engines, the accelerator pedal position sensor could move on its mounting bracket if the pedal is depressed with excessive force. If the sensor stator were to move out of position, it could change the sensor signal output, resulting in a high idle. On vehicles equipped with manual transmissions, if the clutch were to be depressed during operation, the engine could rise to governed RPMs 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, which could increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will recalibrate the engine Electronic Control Module (ECM) to eliminate the high idle condition.

• Engine#2015448October 5, 2015

  11 units affected

  On certain vehicles, the Engine Control Module (ECM) may develop an internal electrical short circuit that could blow a fuse in the ECM's electrical supply circuit. This could cause the engine to stall without warning and prevent the vehicle from being restarted. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash causing property damage and/or personal injury. Correction: Dealers will replace the ECM.

• Structure#2015434September 28, 2015

  188 units affected

  On certain vehicles, the fifth wheel locking mechanisms could be susceptible to damage and/or wear. This could cause the locking mechanism to fail properly engage, potentially resulting in a towed trailer unit separating from the truck tractor. As a result, the trailer could strike another vehicle, stationary object, or bystander, causing injury and/or damage to property. Correction: Fontaine dealers will replace all Ultra LT fifth wheel units with Ultra NT model fifth wheel units.

• Structure#2015214May 20, 2015

  278 units affected

  On certain vehicles, the weld joint between the upper stack tail pipe and the vertical exhaust pipe may crack and allow the exhaust pipe to separate from the vehicle. The pipe falling on the road surface could create a safety hazard potentially resulting in a crash causing injury and/or damage to property. Correction: Dealers will replace the stack tail pipes with an approved replacement part.

• Electrical#2015171April 22, 2015

  8,552 units affected

  On certain vehicles, a double battery (24 volt) jump start or electrical load dump could result in an overvoltage condition of the linear power module (LPM) which is used to control the heater/air conditioning blower motor speed. If this were to occur, this overvoltage condition could lead to the LPM overheating, causing smoke, and increase the risk of fire, which could result in injury and/or damage to property. Correction: Dealers will replace the LPM with an upgraded design.

• Brakes#2015120March 18, 2015

  493 units affected

  On certain vehicles, brake chamber diaphragm(s) may not be properly seated. This could lead to brake drag, causing brake overheating or unintended spring brake application. These issues could increase the risk of a crash causing injury and/or property damage. Correction: Dealers will replace the brake chambers. Note: This is an expansion of recall 2014-573.

• Brakes#2014573December 17, 2014

  264 units affected

  On certain vehicles, brake chamber diaphragm(s) may not be properly seated. This could lead to brake drag, causing brake overheating or unintended spring brake application. These issues could increase the risk of a crash causing injury and/or property damage. Correction: Dealers will affect repairs as necessary.

• Heater And Defroster#2014484October 30, 2014

  1,424 units affected

  On certain vehicles equipped with a no-idle heating, ventilation and air conditioning (HVAC) module, the electrical harness supplying power to the module may not be of sufficient size, which could cause a voltage drop in the harness and an increase in resistance and heating at the connector. This could cause a fire, potentially resulting in injury and/or damage to property. Correction: Dealers will install a revised harness.

• Brakes#2014141April 22, 2014

  169 units affected

  On certain vehicles equipped with air disc brakes, the brake caliper bolts may have been insufficiently tightened, or an insufficient number of bolts may have been installed at time of vehicle assembly. Loose or missing bolts could allow a caliper to detach from its mount, resulting in partial loss of brake function, which could increase stopping distance and increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will replace missing bolts, if any, and tighten all caliper bolts to the specified torque.

• Label#2014140April 22, 2014

  417 units affected

  Certain trucks may not comply with Canadian Motor Vehicle Safety Regulations. Vehicles may not bear a compliance label, or the compliance label may be missing Gross Vehicle Weight Rating (GVWR) information. This could result in vehicle overloading, increasing the risk of a crash causing injury and/or damage to property. Correction: Owners will be sent a revised compliance label.

• Brakes#2014049February 20, 2014

  64 units affected

  On certain vehicles, brake s-cam bracket assemblies on the steering axle could fracture, causing an inoperative brake on the affected wheel end. This could cause the vehicle to pull to one side while braking and/or increase stopping distances, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will affect repairs.

• Accessories#2013314September 19, 2013

  185 units affected

  On certain trucks equipped with the electronic fifth wheel jaw release system, incorrect air line routing could allow the fifth wheel jaw to release without driver input. This could result in a trailer separating from the truck, resulting in a possible hazard to other road users and increasing the risk of a crash causing injury and/or property damage. Correction: Dealers will inspect air line routing and correct if necessary.

• Structure#2013122April 17, 2013

  3,991 units affected

  On certain trucks, the sunshade (an exterior visor mounted above the windshield) may not have been fastened to the cab roof correctly during the manufacturing process. A sunshade separating from the vehicle could strike another vehicle, a stationary object, or a bystander, causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, secure the sunshade mounts.

• Steering#2012349October 16, 2012

  924 units affected

  On certain vehicles, the steering wheel may have been manufactured incorrectly and could fail. This could allow the steering wheel to separate from the steering wheel hub. Should this occur while the vehicle is underway, the driver would lose steering control, which could result in a crash causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, replace the steering wheel assembly.

• Wheels#2012219July 18, 2012

  40 units affected

  On certain trucks equipped with the Harley Davidson option package, the road wheels may develop cracks. Over time, the cracks may progress to the point of wheel failure, which could result in separation of the wheel from the axle. A wheel separating from the vehicle could cause a loss of control and a crash. In addition, the errant wheel assembly could strike a vehicle, stationary object or a bystander. These issues could result in property damage and/or personal injury. Correction: Dealers will replace the wheels.

• Electrical#2012147May 1, 2012

  2,543 units affected

  On certain trucks equipped with a MaxxForce 11 or 13 engine, the positive alternator cable may rub against the high pressure power steering hose. Continued contact could wear through the alternator cable's insulation, which could cause an electrical short circuit. An electrical short could result in a vehicle fire causing property damage and/or personal injury. Correction: Dealers will install a bracket to route the alternator wires away from the power steering hose. Note: This recall supersedes recall 2011302.

• Wheels#2010310September 14, 2010

  22 units affected

  On certain vehicles equipped with styled aluminum wheels, cracks may develop in the spokes. Over time, the cracks may progress to the point of wheel failure, possibly resulting in wheel separation from the vehicle. Wheel separation increases the risk of a crash which may result in property damage, personal injury or death. Correction: Dealers will replace the wheels.

• Visual System#2010286August 26, 2010

  5,404 units affected

  On certain trucks, the passenger side windshield wiper linkage rod may separate from either the wiper motor drive arm or the passenger side pivot assembly. If the linkage separates, the passenger side wiper arm will no longer operate which could lead to reduced driver visibility. Decreased driver visibility may increase the risk of a crash possibly resulting in property damage, personal injury, or death. Correction: Dealers will install a redesigned windshield wiper linkage assembly.

• Steering#2010200June 11, 2010

  153 units affected

  On certain trucks, the fastener that clamps the pitman arm to the steering gear shaft may not have been torqued to specifications during vehicle assembly. This could cause wear of the interconnecting splines of the arm and shaft, possibly allowing the pitman arm to slip over the shaft, resulting in a reduction of steering control which could increase the risk of a crash causing property damage, personal injury or death. Correction: Dealers will replace the tubular shaped spacer bracket with a solid spacer block.

• Electrical#2010096March 23, 2010

  3,488 units affected

  On certain vehicles equipped with an optional jump start stud, corrosion at the base of the stud may cause an electrical short between the stud and battery box resulting in a vehicle fire causing property damage, personal injury, or death. Correction: Dealers will install a new redesigned jump start stud.

• Brakes#2008421November 21, 2008

  2,522 units affected

  On certain trucks, the service brake air line between the tractor protection valve and the fast brake module may separate from the fast brake module. This would result in a loss of trailer service brakes, which could increase stopping distances, possibly causing a vehicle crash resulting in property damage, personal injuries or death. Correction: Dealers will replace the fast break module and reroute air lines to eliminate line tension.

Canadian data updated August 24, 2026