Description

NAVISTAR IC BUS-AE BUS SERVICE MANUAL

What does this catalog contain?

NAVISTAR IC BUS-AE BUS SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR IC BUS-AE BUS SERVICE MANUAL includes:

• Numbered table of contents easy to use so that you can find the information you need fast.
• Detailed sub-steps expand on repair procedure information.
• Numbered instructions guide you through every repair procedure step by step.
• Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Bold figure number help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every procedure.
• Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE NAVISTAR IC BUS-AE BUS SERVICE MANUAL

1. IDENTIFICATION…………………………………………………………………………………….. 1
1.1. VEHICLE CERTIFICATION TAG………………………………………………………………. 1
1.2. BODY SERIAL NUMBER PLATE………………………………………………………………. 1
1.3. REPORTING SAFETY DEFECTS……………………………………………………………… 1
2. DESCRIPTION……………………………………………………………………………………….. 2
2.1. EXTERIOR (DRIVER SIDE)……………………………………………………………………. 2
Windshield……………………………………………………………………………………… 2
Traffic-Stop Arm……………………………………………………………………………….. 2
Driver-Side Door……………………………………………………………………………….. 2
Driver-Side Window……………………………………………………………………………. 2
Emergency-Exit Windows……………………………………………………………………… 2
End Caps………………………………………………………………………………………. 3
Emergency-Exit Roof Hatch……………………………………………………………………. 3
Battery Compartment………………………………………………………………………….. 3
2.2. EXTERIOR (PASSENGER SIDE)……………………………………………………………… 4
Passenger Windows…………………………………………………………………………… 4
Roof-Mounted Strobe Light…………………………………………………………………….. 4
Passenger-Entry Door…………………………………………………………………………. 4
Rear-View Mirrors……………………………………………………………………………… 4
Wheelchair-Lift Door…………………………………………………………………………… 4
Radio Antenna…………………………………………………………………………………. 5
Rubber Fenders……………………………………………………………………………….. 5
2.3. EXTERIOR (REAR)……………………………………………………………………………. 6
Warning Lights…………………………………………………………………………………. 6
Emergency-Exit Door………………………………………………………………………….. 6
Clearance Lights……………………………………………………………………………….. 6
D.O.T. Side-Marker Lights and Reflectors……………………………………………………… 7
Rear Body Lights………………………………………………………………………………. 7
Rear Bumper Assembly………………………………………………………………………… 7
Body Tie-Downs……………………………………………………………………………….. 7
Destination-Board Lights……………………………………………………………………….. 7
Static Roof Vent………………………………………………………………………………… 7
Windshield Wipers……………………………………………………………………………… 7
2.4. INTERIOR……………………………………………………………………………………… 8
Step Well………………………………………………………………………………………. 8
Assist Handrails………………………………………………………………………………… 8
Flooring………………………………………………………………………………………… 9
Crash Barriers…………………………………………………………………………………. 9
Driver Seat…………………………………………………………………………………….. 9
Reflective Road Triangles……………………………………………………………………… 9
Fire Extinguisher……………………………………………………………………………….. 9
First Aid Kit…………………………………………………………………………………… 10
Body Fluid Cleanup Kit……………………………………………………………………….. 10
Passenger Seats……………………………………………………………………………… 10
Seat Tracks…………………………………………………………………………………… 10
Small-Child-Restraint Seat……………………………………………………………………. 11
Instrument Cluster…………………………………………………………………………….. 11
Control Panel…………………………………………………………………………………. 11
Climate Controls………………………………………………………………………………. 11
Light Bars…………………………………………………………………………………….. 12

Lower Glass-Protection Screen………………………………………………………………. 12
Fuel-Sending-Unit Plate………………………………………………………………………. 12
Overhead Compartments…………………………………………………………………….. 13
Rear-View Mirror……………………………………………………………………………… 13
Sun Visor……………………………………………………………………………………… 13
Exterior Light Monitor…………………………………………………………………………. 13
Wheelchair Lift………………………………………………………………………………… 14
Interior Trim Panels…………………………………………………………………………… 16
3. REMOVAL AND INSTALLATION……………………………………………………………………. 17
3.1. WIPER-ARM ASSEMBLY…………………………………………………………………….. 18
Wiper-Arm Assembly – Removal……………………………………………………………… 18
Wiper-Arm Assembly – Installation……………………………………………………………. 20
3.2. WINDSHIELD-WIPER MOTOR………………………………………………………………. 21
Windshield-Wiper Motor – Removal………………………………………………………….. 21
Windshield-Wiper Motor – Installation………………………………………………………… 22
3.3. WINDSHIELD-WIPER BOTTLE AND / OR PUMP MOTOR………………………………….. 22
Windshield-Wiper Bottle and / or Pump Motor – Removal…………………………………….. 22
Windshield-Wiper Bottle and / or Pump Motor – Installation………………………………….. 24
3.4. WINDSHIELD………………………………………………………………………………… 25
Windshield – Removal………………………………………………………………………… 25
Windshield – Installation……………………………………………………………………… 27
3.5. REAR-VIEW MIRRORS………………………………………………………………………. 30
Driver-Side Rear-View Mirror – Removal……………………………………………………… 30
Driver-Side Rear-View Mirror – Installation……………………………………………………. 30
Passenger-Side Rear-View Mirror – Removal………………………………………………… 31
Passenger-Side Rear-View Mirror – Installation………………………………………………. 31
3.6. WARNING, STOP, TURN, AND / OR BACKUP LIGHTS……………………………………… 32
Warning, Stop, Turn, and / or Backup Light – Removal……………………………………….. 32
Warning, Stop, Turn, and / or Backup Light – Installation…………………………………….. 32
Warning, Stop, Turn, and / or Backup Light Bulb (if applicable) – Removal…………………… 33
Warning, Stop, Turn, and / or Backup Light Bulb (if applicable) – Installation…………………. 33
3.7. CLEARANCE LIGHT…………………………………………………………………………. 33
Clearance Light – Removal…………………………………………………………………… 33
Clearance Light – Installation…………………………………………………………………. 34
3.8. SIDE MARKER LIGHTS……………………………………………………………………… 34
Side Marker Light – Removal…………………………………………………………………. 34
Side Marker Light – Installation……………………………………………………………….. 35
3.9. REFLECTORS……………………………………………………………………………….. 36
Reflector – Removal………………………………………………………………………….. 36
Reflector – Installation………………………………………………………………………… 37
3.10. LICENSE-PLATE LIGHT……………………………………………………………………… 37
License-Plate Light – Removal……………………………………………………………….. 37
License-Plate Light – Installation……………………………………………………………… 38
3.11. IGNITION SWITCH WITH INTEGRATED CONNECTOR…………………………………….. 38
Ignition Switch – Removal…………………………………………………………………….. 38
Ignition Switch – Installation………………………………………………………………….. 39
Ignition-Switch Tumbler – Removal…………………………………………………………… 40
Ignition-Switch Tumbler – Installation…………………………………………………………. 42
3.12. HOOD SEAL………………………………………………………………………………….. 42
Hood Seal – Removal………………………………………………………………………… 42

3.13. COWL TRAY…………………………………………………………………………………. 43
Cowl Tray – Removal…………………………………………………………………………. 43
Cowl Tray – Installation……………………………………………………………………….. 44
3.14. PASSENGER-ENTRY DOOR………………………………………………………………… 45
Passenger-Entry Door – Removal……………………………………………………………. 45
Passenger-Entry Door – Installation………………………………………………………….. 48
3.15. DRIVER DOOR………………………………………………………………………………. 49
Driver Door – Removal……………………………………………………………………….. 49
Driver Door – Installation……………………………………………………………………… 52
3.16. DRIVER-DOOR-TRIM PANEL………………………………………………………………… 53
Driver-Door-Trim Panel – Removal…………………………………………………………… 53
Driver-Door-Trim Panel – Installation…………………………………………………………. 55
3.17. VAPOR BARRIER……………………………………………………………………………. 56
Vapor Barrier – Removal……………………………………………………………………… 56
Vapor Barrier – Installation……………………………………………………………………. 56
3.18. WINDOW-SLIDE BLOCK…………………………………………………………………….. 57
Window-Slide Block – Removal………………………………………………………………. 57
Window-Slide Block – Installation…………………………………………………………….. 58
3.19. DRIVER-DOOR GLASS………………………………………………………………………. 59
Driver-Door Glass – Removal………………………………………………………………… 59
Driver-Door Glass – Installation………………………………………………………………. 61
3.20. MODULAR-DOOR-HARDWARE ASSEMBLY………………………………………………… 62
Modular-Door-Hardware Assembly – Removal……………………………………………….. 62
Modular-Door-Hardware Assembly – Installation……………………………………………… 65
3.21. VENT WINDOW, LATCH, AND SEAL………………………………………………………… 66
Vent Window, Latch, and Seal – Removal……………………………………………………. 66
Vent Window, Latch, and Seal – Installation………………………………………………….. 67
3.22. DOOR-LOCK CYLINDER…………………………………………………………………….. 68
Door-Lock Cylinder – Removal……………………………………………………………….. 68
Door-Lock Cylinder – Installation……………………………………………………………… 69
3.23. WINDOW ELECTRIC MOTOR……………………………………………………………….. 70
Window Electric Motor – Removal……………………………………………………………. 70
Window Electric Motor – Installation………………………………………………………….. 71
3.24. REGULATOR-ARM ASSEMBLY……………………………………………………………… 72
Regulator-Arm Assembly – Removal…………………………………………………………. 72
Regulator-Arm Assembly – Installation……………………………………………………….. 75
3.25. OUTER-DOOR HANDLE…………………………………………………………………….. 77
Outer-Door Handle – Removal……………………………………………………………….. 77
Outer-Door Handle – Installation……………………………………………………………… 79
3.26. DOOR LATCH………………………………………………………………………………… 80
Door Latch – Removal………………………………………………………………………… 80
Door Latch – Installation……………………………………………………………………… 81
3.27. INNER-DOOR HANDLE……………………………………………………………………… 82
Inner-Door Handle – Removal………………………………………………………………… 82
Inner-Door Handle – Installation………………………………………………………………. 83
3.28. WEATHER SEALS……………………………………………………………………………. 85
Weather Seals – Removal……………………………………………………………………. 85
Weather Seals – Installation………………………………………………………………….. 85
3.29. WINDOW-RUN CHANNELS………………………………………………………………….. 86
Window-Run Channels – Removal……………………………………………………………. 86

3.30. ELECTRIC-WINDOW AND DOOR-LOCK SWITCH………………………………………….. 88
Electric-Window and Door-Lock Switch – Removal…………………………………………… 88
Electric-Window and Door-Lock Switch – Installation…………………………………………. 88
3.31. DRIVER-ASSIST-STEP ASSEMBLY…………………………………………………………. 89
Driver-Assist-Step Assembly – Removal……………………………………………………… 89
Driver-Assist-Step Assembly – Installation……………………………………………………. 89
3.32. PASSENGER WINDOWS…………………………………………………………………….. 90
Passenger Window – Removal……………………………………………………………….. 90
Passenger Window – Installation……………………………………………………………… 91
3.33. EMERGENCY-EXIT ROOF HATCH………………………………………………………….. 93
Emergency-Exit Roof Hatch – Removal………………………………………………………. 93
Emergency-Exit Roof Hatch – Installation…………………………………………………….. 94
3.34. WHEELCHAIR-ACCESS DOOR……………………………………………………………… 95
Wheelchair-Access Door – Removal………………………………………………………….. 95
Wheelchair-Access Door – Installation……………………………………………………….. 95
3.35. REAR BUMPER………………………………………………………………………………. 96
Rear Bumper – Removal……………………………………………………………………… 96
Rear Bumper – Installation……………………………………………………………………. 97
3.36. TRAFFIC-STOP ARM………………………………………………………………………… 97
Traffic-Stop Arm – Removal…………………………………………………………………… 97
Traffic-Stop Arm – Installation………………………………………………………………… 98
3.37. RUBBER FENDERS………………………………………………………………………….. 98
Rubber Fenders – Removal…………………………………………………………………… 98
Rubber Fenders – Installation………………………………………………………………… 99
3.38. SLIDING BATTERY BOX…………………………………………………………………….. 99
Sliding Battery Box – Removal……………………………………………………………….. 99
Sliding Battery Box – Installation…………………………………………………………….. 101
3.39. STATIC ROOF VENT……………………………………………………………………….. 102
Static Roof Vent – Removal…………………………………………………………………. 102
Static Roof Vent – Installation……………………………………………………………….. 102
3.40. ASSIST HANDRAILS……………………………………………………………………….. 103
Assist Handrail (Rearward) – Removal………………………………………………………. 103
Assist Handrail (Rearward) – Installation……………………………………………………. 103
Assist Handrail (Forward) – Removal……………………………………………………….. 104
Assist Handrail (Forward) – Installation……………………………………………………… 105
3.41. STEP WELL…………………………………………………………………………………. 106
Tread Plate – Removal………………………………………………………………………. 106
Tread Plate – Installation……………………………………………………………………. 106
Tread Plate – Sealing……………………………………………………………………….. 107
Step Well – Removal………………………………………………………………………… 108
Step Well – Installation………………………………………………………………………. 110
3.42. SUN VISOR AND CLIP……………………………………………………………………… 111
Sun Visor and Clip – Removal……………………………………………………………….. 111
Sun Visor and Clip – Installation…………………………………………………………….. 111
3.43. INTERIOR REAR-VIEW MIRROR…………………………………………………………… 112
Interior Rear-View Mirror – Removal………………………………………………………… 112
Interior Rear-View Mirror – Installation………………………………………………………. 112
3.44. GEAR SELECTOR………………………………………………………………………….. 113
Gear Selector – Removal……………………………………………………………………. 113
Gear Selector – Installation………………………………………………………………….. 113

3.45. INSTRUMENT PANEL………………………………………………………………………. 114
Instrument Cluster Assembly – Removal…………………………………………………….. 114
Instrument Cluster Assembly – Installation………………………………………………….. 115
Center Panel – Removal…………………………………………………………………….. 116
Center Panel – Installation…………………………………………………………………… 117
Instrument Panel – Removal………………………………………………………………… 118
Instrument Panel – Installation………………………………………………………………. 126
3.46. SEATS AND SEATING………………………………………………………………………. 129
Driver Seat – Removal………………………………………………………………………. 129
Driver Seat – Installation…………………………………………………………………….. 130
Passenger Seat – Removal…………………………………………………………………. 131
Passenger Seat – Installation……………………………………………………………….. 132
Passenger-Seat Tracks (Optional) – Removal………………………………………………. 133
Passenger-Seat Tracks (Optional) – Installation…………………………………………….. 133
3.47. SEAT BELTS………………………………………………………………………………… 134
Driver Seat Belt – Removal………………………………………………………………….. 135
Driver Seat Belt – Installation……………………………………………………………….. 136
Passenger Lap Seat Belts (Optional) – Removal……………………………………………. 137
Passenger Lap Seat Belts (Optional) – Installation………………………………………….. 137
Passenger Shoulder Seat Belts (Optional) – Removal………………………………………. 138
Passenger Shoulder Seat Belts (Optional) – Installation…………………………………….. 141
3.48. CRASH BARRIERS…………………………………………………………………………. 142
Crash Barrier – Removal……………………………………………………………………. 142
Crash Barrier – Installation………………………………………………………………….. 142
3.49. INTERIOR LIGHT BARS……………………………………………………………………. 143
Interior Light Bars – Removal……………………………………………………………….. 143
Interior Light Bars – Installation……………………………………………………………… 143
3.50. STATIONARY GLASS……………………………………………………………………….. 144
Stationary Glass – Removal…………………………………………………………………. 145
Stationary Glass – Installation……………………………………………………………….. 146
3.51. EMERGENCY-EXIT DOOR AND BUZZER………………………………………………….. 147
Emergency-Exit Door – Removal……………………………………………………………. 147
Emergency-Exit Door – Installation………………………………………………………….. 148
Buzzer – Removal…………………………………………………………………………… 149
Buzzer – Installation…………………………………………………………………………. 150
3.52. LOWER GLASS-PROTECTION SCREEN………………………………………………….. 151
Lower Glass-Protection Screen – Removal………………………………………………….. 151
Lower Glass-Protection Screen – Installation……………………………………………….. 151
3.53. SAFETY EQUIPMENT………………………………………………………………………. 152
Fire Extinguisher – Removal………………………………………………………………… 152
Fire Extinguisher – Installation………………………………………………………………. 152
First Aid Kit – Removal………………………………………………………………………. 153
First Aid Kit – Installation……………………………………………………………………. 153
Reflective Road Triangles – Removal……………………………………………………….. 154
Reflective Road Triangles – Installation……………………………………………………… 154
Body Fluid Cleanup Kit (Optional) – Removal……………………………………………….. 155
Body Fluid Cleanup Kit (Optional) – Installation……………………………………………… 155
3.54. FUEL-SENDING-UNIT PLATE………………………………………………………………. 156
Fuel-Sending-Unit Plate – Removal…………………………………………………………. 156
Fuel-Sending-Unit Plate – Installation……………………………………………………….. 156
3.55. FLOOR MAT………………………………………………………………………………… 157 and more

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