This is the PayStar hood grille fenders service manual, publication S09004, for International 5000i and 9000i conventionals. It documents removal, installation and adjustment of the hood, grille and grille surround, splash panels, mud guards, hood seals and fenders.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | 5000i and 9000i — 5500i, 5600i, 5900i, 9100i, 9200i, 9400i, 9900i, 9900ix |
| System / Group | 5000 Series (PayStar) / Hood Grille Fender |
| Publication no. | S09004 |
| Year / Revision | 10/05/2000 |
| Pages | 125 |
| File size | 2.0 MB |
| Format | |
| Language | English |
Inside the PayStar hood grille fenders
- Description: hood, splash panels, mud guards, hood seals
- Remove hood grille (tilt hood and butterfly hood)
- Remove hood tilt assist spring assembly
- Remove hood shock absorber and hood
- Remove and install splash panels
- Center hood guide adjustment and torque chart
Copyrighted by Navistar in October 2000, the section is built around clearly numbered remove and install procedures with figure callouts for every fastener. It distinguishes tilt-hood and optional butterfly-hood configurations and separates set-forward-axle (SFA) from set-back-axle (SBA) chassis so the correct steps are followed for each cab. Coverage includes the hood grille and grille surround trim, the hood tilt assist spring assembly, hood shock absorbers, the hood itself, chassis- and hood-mounted splash panels, radiator shell hood seals and the fenders. A heat gun is specified for removing grille surround trim, and an assistant is called for whenever the hood assembly is lifted from the vehicle. A torque chart at the end lists values such as 50 to 55 ft-lbs and 80 to 105 ft-lbs for the major hinge and mounting fasteners.
Applicable truck models
Coverage spans SFA and SBA configurations across the 5500i, 5600i, 5900i, 9100i, 9200i, 9400i, 9900i and 9900ix. Torque values include 50 to 55 ft-lbs on key hood hinge fasteners. Verify coverage against your VIN and build sheet on the International Trucks website.
Who needs the PayStar hood grille fenders
Body and collision technicians servicing front-end sheet metal on PayStar and 9000i conventionals use this manual to remove tilt or butterfly hoods safely, replace splash panels and grille trim, and reset center hood guide alignment.
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