This DuraStar cab service manual (publication S160263, 2003) is the factory cab section for International 4100, 4200, 4300, 4400, DuraStar and TerraStar models. It covers the standard, extended and crew cab and the removal and installation of glass, doors and cab hardware.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | 4100, 4200, 4300, 4400, DuraStar, TerraStar |
| System / Group | Cab |
| Publication no. | S160263 |
| Year / Revision | 2003 |
| Pages | 317 |
| File size | 3.8 MB |
| Format | |
| Language | English |
What the DuraStar cab service manual covers
- Description — standard, extended and crew cab
- Vehicle identification number (VIN) tag location
- Electric windshield wipers and washer
- One-piece encapsulated windshield removal
- Rear window glass — with and without van body
- Hood seal, sun shade and sun visor
- Ignition switch and cylinder, instrument panel
- Cab doors, hinges and torque chart
Publication S160263 details one-piece encapsulated windshield replacement, rear window glass on van and non-van bodies, cab doors, hinge service and cab air-suspension mounting, with a torque chart for hinge bolts and striker pins.
Applicable truck models
The cab section applies to International 4100, 4200, 4300, 4400, DuraStar and TerraStar models. Confirm standard, extended or crew cab before service. Brand info is at the International Trucks official website.
Who needs this DuraStar cab service manual
Body shops and fleet technicians use this section to replace windshields, rear glass and door hardware and to reset cab mounts. It is written for trained professionals with the right tools.
Windshield and glass work here is urethane-bonded, so the manual calls for cutting the encapsulation trim, lubricating the cut line with water to stop rebonding, and dry-fitting new glass before final set. Save the push-in fasteners, clips and trim from doors and headliner for reuse, and follow the torque chart for hinge bolts, striker pins and cab-suspension hardware so doors close true and the cab rides level.
The full PDF is available in the DiagTechPro manuals library — a free account is required to download. Each listing shows the exact publication number so you can match the document to your VIN and build date before downloading.
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