International Navistar TranStar ProStar LoneStar 8000-Series Trucks 1993-2020 Workshop Repair Service Manual PDF - MINT8000PROS.zip
A full-service repair guide featuring Electrical Wiring Diagrams for the International/Navistar 8000-Series TranStar and ProStar truck lines, containing everything needed to service, troubleshoot, fix, and rebuild these vehicles at a professional mechanic's level.
This workshop service repair manual for the International Navistar 8000-Series TranStar and ProStar trucks covers:
* 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.
PRODUCT DETAILS:
Total Pages: 31,720 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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CTS-5122K - 2000 , 4000 and 8000 Series September 1993 and Later Electrical Circuit Diagrams.pdf
CTS-5122T - 2000, 4000, 8000 Series Built After February 1, 1996 Electrical Circuit Diagrams.pdf
s04010 - Air Compressor_ Bendix TU-FLO 501, Supersedes CTS-5145 (March 1996) Service Manual.pdf
s09002 - Hood, Grille, and Fenders - 2000, 4000, 8000 (Supersedes CTS-5269) (Feb 1999) Service Manual.pdf
S02005R - Rockwell Front Non-Drive Steering Axle, Supersedes CTS-5046R (April 1996) Service Manual.pdf
S03001K - Air Suspension with Tapered Leaf Springs, Supersedes CTS-5025K (March 1996) Service Manual.pdf
S03002R - Neway Air Suspension, Supersedes CTS-5028R (March 1996) Service Manual.pdf
S03008 - International 4x2 and 6x4 Spring Suspension with Torque Rods, Supersedes CTS-5144 (March 1996) Service Manual.pdf
S03011 - Hendrickson HN-460 Suspension, Supersedes CTS-5221 (March 1996) Service Manual.pdf
S03012 - International Ride Optimized Suspension (IROS) (April 2002) Service Manual.pdf
S03015 - 2007 MY ProStar _ LoneStar MAXXPOWER Front Air Suspension (Oct 2009) Service Manual.pdf
S04003R - Air Compressor_ Bendix TU-Flo 550 and TU-Flo 750, Supersedes CTS-5056R (March 1996) Service Manual.pdf
S04005 - Cam Air Foundation Brakes, Supersedes CTS-5060 (March 1996) Service Manual.pdf
S04006 - Rockwell Automatic Slack Adjusters (Oct 2006) Service Manual.pdf
S04007 - Reconditioning Brake Drums and Shoes, Supersedes CTS-5085 (March 1996) Service Manual.pdf
S04012 - Bobtail Brake Proportioning Relay Valve and LQ-5 Bobtail Limiting Valve, Supersedes CTS-5170 (March 1996) Service Manual.pdf
S04014 - Air Compressor_ Holset SS 296 and QE 296_338, Supersedes CTS-5197 (March 1996) Service Manual.pdf
S04019 - Double Diaphragm Anchorlok Spring Brake, Supersedes CTS-5074 (March 1996) Service Manual.pdf
S04020X - Double Diaphragm MGM Spring Brake, Supersedes CTS-5107X (Sept 1998) Service Manual.pdf
S04029 - Antilock Brakes_Traction Control_ Bendix - Principles, Operation and Service, Supersedes CTS-5246 (March 1996) Service Manual.pdf
S04033 - Antilock Brakes_Traction Control_ Bendix - Troubleshooting, Supersedes CTS-5250 (June 1996) Service Manual.pdf
S04038 EC-17 - Antilock Traction Controller, Supersedes CTS-5292 (Aug 1998) Service Manual.pdf
S04053 - ECE-13 Brake System (2010) Service Manual.pdf
S04055 - MCAC 465 Air Compressor (Dec 2010) Service Manual.pdf
S05003Y - Power Steering Gear_ TRW _ ROSS-TAS 40, 55, 65 and 85, Supersedes CTS-5215 (Sept 2000) Service Manual.pdf
S05012 - Steering Column Assembly, Tilt_Telescoping Supersedes CTS-5167 (May 1996) Service Manual.pdf
S05013 - Steering Column Assembly, Standard and Tilt, Supersedes CTS-5168 (April 1996) Service Manual.pdf
S05015Y - Power Steering Gear_ Sheppard M-Series, Supersedes CTS-5262 (Sept 2000) Service Manual.pdf
S05016 - Steering Wheel Removal and Installation (Sept 2010) Service Manual.pdf
S05018 - LoneStar Steering Column Assembly, Tilt _ Telescoping (Oct 2011) Service Manual.pdf
S05021 - Steering Wheel and Steering Column Assembly (July 2012)Manual - Truck3_10_2016 12_00_00 AM.pdf
S05025 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
S07003 - Exhaust Aftertreatment and Diesel Particulate Filter (DPF) (Oct 2009) Service Manual.pdf
S08003 - Steering Wheel and Steering Column Assembly (Jan 2012) Service Manual.pdf
S08018 - 9100, 9200, 9300, 9400, 9600, 9700, and 9800 Model Alternator (Delco-Remy 26-SI Series), Supersedes CTS-5077 (March 1996) Service Manual.pdf
S08034X - Instruments, Supersedes CTS-5088K (Oct 1999) Service Manual.pdf
S08036 - Starting Motors (Delco-Remy), Supersedes CTS-5054 (March 1996) Service Manual.pdf
S08154X - Speedometer _ Tachometer Diagnostics and Service, Supersedes CTS-5257 (Oct 1999) Service Manual.pdf
S08155X - Instruments (New Data Link Driven Instrument Cluster), Supersedes CTS-5228 (Oct 1999) Service Manual.pdf
S08186 - 2000, 4000, 8000 Models Built October 1, 1998 To September 30, 1999 Electrical Circuit Diagrams.pdf
S08186X - 2000, 4000, 8000 Models Built October 1, 1999 and After Electrical Circuit Diagrams.pdf
S08230- Electrical System Troubleshooting Guide, Supersedes CTS-5300 (July 1999) Service Manual.pdf
S08287 - 1000-4000, 7000, 8000 Fuses and Circuit Breakers Supersedes CTS-4410 (June 2001) Service Manual.pdf
S08300 - Body Builder Electrical Data Book for Models Built January 2001 to February 28, 2007 Supersedes PBB-73000B (Aug 2008) Service Manual.pdf
S08300, Formerly PBB-73000B - 3200 4000 7000 8000 - Body Builder Data Book.pdf
S08312 - Aware Vehicle Intelligence System Diagnostic Trouble Codes (June 2005) Service Manual.pdf
S08315 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, MXT, RXT Models Built Oct. 1, 2005 to Feb. 28, 2007 Electrical Circuit Diagrams.pdf
S08322 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600, RXT Models Built March 1, 2007 to March 18, 2008 Electrical Circuit Diagrams.pdf
S08322 - 3200, 4100, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, RXTModels Built March 1, 2007 to March 18, 2008 Wiring Diagrams.pdf
S08324 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600, CXT, DuraStar, RXT, TranStar, and WorkStar Models Built After March 01, 2007 Electrical System Troubleshooting GuideDiagnostic Trouble Codes.pdf
S08327 - 2007 - 2010 Body Controller (BC) Diagnostic Trouble Codes Service Manual.pdf
S08339 - 2007 MY ProStar _ LoneStar Chassis Built January, 2007 and After Electrical Circuit Diagrams Manual.pdf
S08354 - 2007 MY ProStar _ LoneStar Models Built After January 2007 Electrical System Troubleshooting Guide Manual.pdf
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S08360 - ProStar _ LoneStar Models Built After June 2010 Electrical System Troubleshooting Guide Manual.pdf
S08361 - 2010 Electrical Troubleshooting.pdf
S08361 - TerraStar, TranStar, and WorkStar Models Built May 2010 and Later Electrical System Troubleshooting Guide Service Manual.pdf
S09006 - Hood, Grille, Fenders and Bumper - 8500 (June 2002) Service Manual.pdf
S09008 - Hood, Grille, Fenders and Bumper - 8600 (Nov 2002) Service Manual.pdf
S09016 - Hood, Grille, Fenders and Bumper (Dec 2009) Service Manual.pdf
S11001S - Spicer 14-Inch (356 mm) and 15 1_2-Inch (394 mm) Two-Plate, Pull-Type Clutch Supersedes CTS-5043S (March 1996) Service Manual.pdf
S11003 - Spicer 14-Inch (355.6 mm) Stamped Angle-Spring Clutch Supersedes CTS-5140 (March 1996) Service Manual.pdf
S11004 - Spicer 14 Inch (350 mm) Solo Clutch Supersedes CTS-5256 (March 1996) Service Manual.pdf
S11006R - Clutch Control Linkage Supersedes CTS-5053R (Oct 2002) Service Manual.pdf
S11014 - Hydraulic Clutch Service Manual 2010 Service Manual.pdf
S11018 - 2011 Hydraulic Clutch Service Manual.pdf
S12001J - Fan Drive Clutch_ Kysor 1090 Supersedes CTS-5015J (March 1996) Service Manual.pdf
S12004R - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual.pdf
S12005 - Fan Drive Clutch_ Horton On_Off, Supersedes CTS-5083R (March 1996) Service Manual.pdf
S12008 - Radiator, Removal and Replacement (2012) Service Manual.pdf
S12011 - Radiator _ Cooling System (Aug 2012) Service Manual.pdf
S12021 - 2007 MY ProStar _ LoneStar Radiator _ Cooling System (Aug 2012) Service Manual.pdf
S12036 - Radiator_Cooling System (2010) Service Manual.pdf
S13006H - 6 Speed Transmissions International Model ES52-7A and ESO65-7A 6-Plus Service Manual.pdf
S13007 - 13 Speed & 18 Speed Transmissions Eaton RTLO-713 _ 18 Series Supersedes CTS-5176 (June 1996) Service Manual.pdf
S13008 - 6 Speed Transmissions Eaton Series FS-5106 and FS-6206 Supersedes CTS-5179 (June 1996) Service Manual.pdf
S13016 - 7 Speed Transmissions Spicer PS110-7, PS145-7 Supersedes CTS-5188 (March 1996) Service Manual.pdf
S13017 - 10 Speed Transmissions Eaton RTLO Series Supersedes CTS-5196 (March 1996) Service Manual.pdf
S13018 - 8 Speed, 9 Speed, And 13 Speed Transmissions Eaton Series Supersedes CTS-5205 (June 1996) Service Manual.pdf
S14002 - 2 SPEED AXLE SHIFT UNIT_ EATON (Supersedes CTS-5166) Service Manual.pdf
S14004 - SINGLE REDUCTION, TANDEM AXLES_ SPICER J400-S, W460-S (Supersedes CTS-5259) Service Manual.pdf
S14006T - SINGLE REDUCTION CARRIERS_ ROCKWELL (Supersedes CTS-5080T) Service Manual.pdf
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S14013 - SINGLE REDUCTION, TANDEM DRIVE AXLES_ EATON (Supersedes CTS-5213) Service Manual.pdf
S14016 - 2 SPEED AND DOUBLE REDUCTION SINGLE DRIVE AXLES_ EATON (Supersedes CTS-5195) Service Manual.pdf
S15001 - Dual Draw Dual Return Fuel Tanks (Formerly CTS-5245) Service Manual.pdf
S16003 - Repair Instructions for Fiberglass and Plastic (ABS) Material (Formerly CTS-5173) Service Manual.pdf
S16007S - Cab_ 2000, 4000, AND 8000 (Formerly CTS-5130S) Service Manual.pdf
S16012V - Air Conditioning Basic Theory, System Diagnosis and Service (With R-12 Refrigerant System) (Formerly CTS-5062) Service Manual.pdf
S16016 - Air Conditioning - Heater System_ 2000, 4000, and 8000 - 12_06_1994 and After Formerly (CTS-5227) Service Manual.pdf
S16017X - Air Conditioning Compressor and Clutch, Two Cylinder Reciprocating Type - After 01_01_1993 (R-134A) (Formerly CTS-5241) Service Manual.pdf
S16022Y - Air Conditioning Protection and Diagnostic System (APAds) Description, Operation, Troubleshooting, Remove, Install, and Electrical Circuit Diagrams Maintenance Manual.pdf
S16025 - HEAT VENTILATION AIR CONDITIONING (HVAC), Orifice Tube System, Pre-March 2007 - 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600Manual - Truck2_16_2011 12_00_00 AM.pdf
S16034 - HEAT VENTILATION AIR CONDITIONING (HVAC), TXV System, March 2007 - 2009 3200, 4100, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 7700, 8500, 8600 Models, CXT, DuraStar, TranStar, WorkStar and RXT Service Manual.pdf
S16038 - CAB_ 7300, 7400, 7500, 7600, 7700, 8500, 8600, TranStar, and WorkStar Models Service Manual.pdf
S16039 - Heat Ventilation Air Conditioning (HVAC) System and TXV System For 2007 Service Manual.pdf
S16043 - 2009 12V DC No Idle HVAC Service Manual.pdf
S16046 - 3200 Bus, DuraStar, TerraStar, TranStar, WorkStar Models Heat Ventilation Air Conditioning (HVAC) for 2010 Service Manual.pdf
S16053 - Heat Ventilation Air Conditioning (HVAC) for 2010 - South Africa _ 7000 RHD AND 8000 RHD Service Manual.pdf
S082503A - Electrical System Troubleshooting Guide Models Built After 05_20_2003 (Apr 2004) Service Manual.pdf
S082503 - Electrical System Troubleshooting Guide Models Built 10_16_2000 to 05_20_2003 (Jan 2008) Service Manual.pdf
S082503 - TRUCK SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING GUIDE — 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Before 05_20_2003.pdf
S082504 - 3200, 4100, 4200,4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models (May 2003 to Feb 2007) Electrical Troubleshooting.pdf
S082504 - Electrical System Troubleshooting Guide Models Built 05_20_2003 to 02_28_2007 (Jan 2008) Service Manual.pdf
S082852 - 4200, 4300, 4400, 7300, 7400, 7500, 8500, 8600 Models Built January 1, 2002 To September 30, 2002 Electrical Circuit Diagrams (Jan 2002)Circuit Diagrams3_30_2016 12_00_00 AM.pdf
S082852A - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built October 1, 2002 to September 15, 2003 Electrical Circuit Diagrams (Oct 2002)Circuit Diagrams3_30_2016 12_00_00 AM.pdf
S082853 - 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 Models Built September 16, 2003 to March 10, 2004 Electrical Circuit Diagrams.pdf
S082854 - Wiring Diagrams (2004 to 2005).pdf
TABLE OF CONTENTS
00000003161 - 2013 Hood Grille Fenders Bumper Service Manual....1
toc....3
Table of Contents....3
1. DESCRIPTION....5
1.1. BUMPER....5
Two Piece Tilt-Away Bumper....5
One Piece Stationary Bumper....5
Three Piece Tilt-Away Bumper....6
Three Piece Stationary Bumper....6
1.2. GRILLE AND BUG SCREEN....7
1.3. Hood Assembly....7
1.4. Hood Tilt Assist....7
1.5. HOOD SEAL....7
1.6. SPLASH SHIELDS....7
1.7. AIR INTAKE....7
1.8. FENDER....7
1.9. FENDER EXTENSIONS....7
1.10. Headlight Assembly....7
2. REMOVE AND INSTALL PROCEDURES....8
2.1. TILT-AWAY BUMPER....9
Two Piece Tilt-Away Bumper – Removal....9
Two Piece Tilt-Away Bumper – Installation....12
2.2. two piece TILT-AWAY BUMPER PANELS....13
Two Piece Tilt-Away Bumper Panel – Removal....13
Two Piece Tilt-Away Bumper Panel – Installation....18
2.3. BUMPER LATCH....19
Bumper Latch – Removal....19
Bumper Latch – Installation....19
2.4. TILT BRACKET....20
Tilt Bracket – Removal....20
Tilt Bracket – Installation....22
2.5. one piece STATIONARY BUMPER....23
One Piece Stationary Bumper-Removal....23
One Piece Stationary Bumper-Installation....24
2.6. one piece stationary Bumper filler panels....25
One Piece Stationary Bumper Filler Panel – Removal....25
One Piece Stationary Bumper Filler Panel – Installation....25
2.7. three piece BUMPER....26
Three Piece Bumper Seal-Removal....26
Three Piece Bumper Upper Reinforcement Tubes-Removal....27
Three Piece Bumper Lower Reinforcement Tubes-Removal....28
Three Piece Bumper Left and Right Bumper Panel-Removal....29
Three Piece Bumper Fixed Assembly-Removal....30
Three Piece Bumper Air Intake Grill-Removal....31
Three Piece Bumper Air Intake Grill-Installation....32
Three Piece Bumper Fixed Assembly-Installation....33
Three Piece Bumper Left and Right Bumper Panel-Installation....34
Three Piece Bumper Lower Reinforcement Tubes-Installation....35
Three Piece Bumper Upper Reinforcement Tubes-Installation....36
Three Piece Bumper Seal-Installation....37
2.8. GRILLE AND BUG SCREEN....38
Grille and Bug Screen – Removal....38
Grille and Bug Screen – Installation....39
2.9. SPLASH SHIELDS....40
Splash Shields – Removal....40
Splash Shields – Installation....42
2.10. HOOD....43
Hood – Removal....43
Hood – Installation....48
Hood – Adjustment....50
2.11. Hood Tilt assist....52
Hood Tilt Assist – Removal....52
Hood Tilt Assist – Installation....54
2.12. Torsion Bars....55
Torsion Bar – Removal....55
Torsion Bar – Installation....56
2.13. Hood Latch....57
Hood Latch – Removal....57
Hood Latch – Installation....58
2.14. Hood Mirror....59
Hood Mirror – Removal....59
Hood Mirror – Installation....60
2.15. Hood Seal....61
Hood Seal – Removal....61
Hood Seal – Installation....61
2.16. Hood and fender panels....62
Hood and Fender Panel – Removal....64
Hood and Fender Panel – Installation....72
2.17. FENDER EXTENSIONS....76
Fender Extensions – Removal....76
Fender Extensions – Installation....77
2.18. Headlight Assembly....78
Headlight Assembly – Removal....78
Headlight Assembly – Installation....79
Headlight Bulb Replacement....79
Headlight Adjustment....80
tables....81
Table 1Torque Chart....81
0000001601 - ProStar + Radiator, Cooling System with SCR Service Manual....82
toc....84
Summary of Changes....84
1. General Description....90
1.1. Deaeration Tank....92
1.2. Fan Shroud....92
1.3. A/C Condenser....92
1.4. Transmission Oil Cooler....92
1.5. Radiator....92
1.6. Charge Air Cooler....92
1.7. Low-Temperature Radiator....92
1.8. Fan Drive....93
1.9. Power Steering Oil Cooler....93
2. Removal and Installation....94
2.1. Coolant Drain, Pressure Test, and Fill Procedures....95
Coolant Drain Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended)....97
Pressure Test Procedure – Navistar ® 11, 13, 15, and Cummins® ISX15 (Recommended)....99
Coolant Fill Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended)....100
Coolant Drain Procedure – Navistar ® 11, 13, 15, Cummins® ISX15 (Optional)....102
Coolant Fill Procedure – Navistar ® 11, 13, 15 (Optional)....103
Coolant Fill Procedure – Cummins® ISX Engines (Optional)....105
2.2. Grille....106
Grille – Removal....106
Grille – Installation....106
2.3. Deaeration Tank – Navistar ® Engines....108
Deaeration Tank Removal – Navistar ® 11, 13, 15....108
Deaeration Tank – Installation Navistar ® 11, 13, 15....109
2.4. Deaeration Tank – Cummins® isx engines....109
Deaeration Tank Removal – Cummins® ISX15....110
Deaeration Tank Installation – Cummins® ISX15....110
2.5. A/C Condenser....112
A/C Condenser Removal – Navistar ® 11, 13 ....112
A/C Condenser Installation – Navistar ® 11 or 13 ....114
A/C Condenser Removal – Navistar ® 15 Liter ....115
A/C Condenser Installation – Navistar® 15 Liter ....116
A/C Condenser Removal – Cummins® ISX15 ....117
A/C Condenser Installation – Cummins® ISX15....118
2.6. Fan Shroud....119
Fan Shroud Removal – Navistar ® 11, 13....119
Fan Shroud Installation – Navistar® 11, 13 Liter ....124
Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 ....125
Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 ....127
Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ....128
Fan Shroud Installation – (Three-Piece Lower) Navistar ® 15....128
Fan Shroud (One-Piece) Removal – Navistar ® 15....129
Fan Shroud Installation – (One-Piece) Navistar ® 15....131
Fan Shroud Removal – (Two-Piece) Cummins® ISX15....131
Fan Shroud Installation – (Two-Piece) Cummins® ISX15....136
2.7. Radiator Fan....138
Radiator Fan Removal – Navistar ® 11, 13....138
Radiator Fan Installation – Navistar® 11, 13 ....139
Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15....140
Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15....140
Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15....141
Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar ® 15....142
Radiator Fan Removal – Cummins® ISX15....142
Radiator Fan Installation – Cummins® ISX15....142
2.8. Fan Drive....144
Fan Drive Removal – Navistar ® 11, 13....144
Fan Drive Installation – Navistar ® 11, 13....145
Fan Drive Removal – Navistar® 15....146
Fan Drive Installation – Navistar® 15....147
Fan Drive Assembly Removal – Cummins® ISX15 (Horton)....147
Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ....148
2.9. Fan Belt....150
Fan Belt Removal – Navistar ® 11, 13....150