sb54296

54-296
Fuel Level Sending Unit Retrofit
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
Freightliner
Service Bulletin
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
Description of Revisions: This bulletin replaces the version dated
May 2017. Instructions for removing the fuel level sender float
have been updated.
General Information
A new improved fuel-level sending unit, manufactured by KUS, is available for retrofitting the fuel-level sending
unit on all Freightliner vehicles. No parameter changes are required. A new connector is required for the retrofit.
See Fig. 1.
Refer to Fig. 2 for this procedure.
1
2
10/27/2016
1
f470692
Pigtail wires can be attached either way.
3
UP
4
Fig. 1, New Connector Pigtail
6
5
7
8
08/23/2016
f470690
The orientation arrow on the unit must point outboard.
1. Harness Zip Tie Anchor Point
2. Receptacle, Chassis-Harness Connector
3. Orientation Arrow
4. Gasket Spacer (5)
5. Gasket Alignment Notch
6. Gasket
7. Float
8. Sensor Tube
Fig. 2, Fuel-Level Sending Unit
Freightliner Service Bulletin, 06/20/2017
Page 1
54-296
Freightliner
Service Bulletin
Fuel Level Sending Unit Retrofit
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
Replacement Procedure
1. Park the vehicle on a level surface, shut down the engine, and set the parking brakes. Chock the tires.
2. If needed, remove the side fairing.
3. Disconnect the fuel-level sending unit harness connector.
4. Remove the five fasteners from the flange of the fuel-level sending unit and discard them.
5. Remove and discard the P-clamp from the chassis harness.
6. Lift the fuel-level sending unit out of the hole in the tank.
7. Install the gasket on the new KUS fuel-level sending unit, making sure the "UP" side of the gasket is
against the unit head, and the alignment notch on the sender aligns with notch on the gasket. See Fig. 3.
B
2
A
1
11/09/2016
f470690a
A. Alignment Notch
B. Alignment Tab
Fig. 3, Installing the Gasket
NOTICE
There is only one correct way to install the fuel-level sending unit. The orientation arrow on the top of
the sending unit must point outboard. See Fig. 2, item 3. Incorrect installation will damage the unit, and
possibly the fuel tank, leading to inaccurate fuel-level readings and fuel leaks.
NOTE: If it is necessary to remove the KUS unit once it is in the tank, it may be necessary to lift the
float to the top of the shaft in order to achieve sufficient clearance to remove the unit. A coat hanger
or aluminum welding rod shaped into a hook can be used for this purpose and is the preferred
method. Bend a coat hanger or aluminum welding rod 90 degrees and form a hook at the end 1-inch
Page 2
Freightliner Service Bulletin, 06/20/2017
54-296
Fuel Level Sending Unit Retrofit
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
Freightliner
Service Bulletin
long and 1-inch wide as shown in Fig. 4. See Fig. 5 for an example of the hook around the float. A
magnetic retrieval tool can also be used. See Fig. 6 for an example. It may take several attempts to
attach the magnet to the float. Also, if there is limited access, it may be necessary to adjust the cab
height to its maximum.
8. Position the fuel-level sending unit and gasket in the hole in the tank, making sure that the orientation arrow
on the top of the sending unit is pointing outboard. See Fig. 7.
B
A
A
B
06/19/2017
06/19/2017
f470702
A. Bend the coat hanger or welding rod 90 degrees.
B. Form a hook at the end 1-inch long and 1-inch
wide.
f470700
A. Positioning the hook to lift the float.
Fig. 5, Lifting the Float
Fig. 4, Making the Hook Tool
Freightliner Service Bulletin, 06/20/2017
Page 3
54-296
Freightliner
Service Bulletin
Fuel Level Sending Unit Retrofit
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
2
1
05/10/2017
1. Magnetic Tool
f546728
2. Float
Fig. 6, Using a Magnetic Tool to Lift the Float
NOTICE
Tapping the screw holes in a new tank requires more torque than the recommended final tightening
torque. The self-tapping fasteners will completely tap the tank wall before they are seated. Failure to
follow the proper procedure will damage the tank and cause leaks.
9. Install new fasteners.
If installing the fuel-level sending unit in a new tank, start all five of the self tapping fasteners through the
tank wall before applying the final tightening torque.
If installing the fuel-level sending unit in a used tank, start all five self tapping screws until contact is made
with the top plate of the fuel-level sending unit. Do not tighten the screws at this time.
NOTICE
Do not over tighten the fasteners. Exceeding the recommended torque specification can strip out the
holes in the tank, requiring tank repair or replacement.
10. Using the tightening sequence shown in Fig. 8, and even progression to distribute the torque evenly around
the fuel-level sending unit, sequentially tighten the screws 15 to 25 lbf·in (160 to 212 N·cm).
NOTE: When attaching the new pigtail, each wire can be connected to either wire of the chassis
harness.
11. Cut the old connector from the fuel-level sending unit harness, and splice the new pigtail to the chassis
harness. See Fig. 9.
Page 4
Freightliner Service Bulletin, 06/20/2017
54-296
Fuel Level Sending Unit Retrofit
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
Freightliner
Service Bulletin
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
4
2
1
1
11/02/2016
f470696
The orientation arrow on the unit must point outboard.
1. Orientation Arrow
Fig. 7, Sending Unit Orientation
3
5
11/17/2016
f470697
Tighten the screws in this order.
Fig. 8, Tightening Sequence
12. Connect the harness to the fuel-level sending unit.
13. Secure the harnesses to the sender with a zip-tie. See Fig. 10. Do not use a P-Clamp.
1
10/27/2016
f470693
Fig. 9, New Pigtail Installation
Freightliner Service Bulletin, 06/20/2017
11/02/2016
f470695
1. Zip-Tie
Fig. 10, Harness Connected and Secured
Page 5
54-296
Fuel Level Sending Unit Retrofit
Freightliner
Service Bulletin
> FLA COE
> FLB COE
> FLD Conventional
> Business Class
> FLC 112 Conventional
> Century Class Conventional
> Argosy COE
Cargo
> Columbia
> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD
> New Cascadia
Parts
Parts are available through the PDC.
Tank
22-inch Cylindrical
23-inch Cylindrical
25-inch Cylindrical
Fuel Tanks with Associated Senders and Gaskets
Medallion
SSI Sender (focus
Old Gasket
KUS Gasket*
Angular Sender
tube)
A22-68359-003
N/A
06-95042-000
A22-68419-023
A22-68359-000
(A22-68428-023)
06-94788-000
22-27156-000
A22-68419-025
A22-68359-001
(A22-68428-025)
A22-68359-002
N/A
06-95042-000
26-inch Cylindrical
312 mm
A22-68359-010
N/A
Rectangular
378 mm
A22-68359-011
N/A
Rectangular
C1TF 9276 C
462 mm
A22-68359-012
N/A
Rectangular
407 mm BetweenA22-66426-002
N/A
Rail Steel
Adaptor Harness, Service Only. Converts Medallion to KUS on trucks in the field.
KUS Linear
Sender
66-00939-022
66-00939-023
66-00939-025
66-00939-026
66-00939-312
66-00939-378
06-95042-000
66-00939-462
66-00939-407
A66-06600-000
* Reference only. KUS sensors include gaskets.
Table 1, Fuel Tanks with Associated Senders and Gaskets
Warranty
This bulletin is informational only. Warranty does not apply.
Page 6
Freightliner Service Bulletin, 06/20/2017