FL702

Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Subject: FCCC XCP Chassis Power Steering Hoses
Models Affected: Specific Freightliner Custom Chassis XCP chassis manufactured April 26, 2013, through January 17, 2015.
General Information
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Freightliner Custom Chassis
Corporation, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned
above.
There are approximately 125 vehicles involved in this campaign.
On certain rear engine chassis, the power steering fluid temperature may exceed the hose material ratings. This
may lead to hose failure with a sudden loss of steering fluid and power assist. A sudden loss of steering assist
without warning could result in a vehicle crash.
To remedy the issue the suspect power steering hose will be replaced with one of higher temperature rating.
REVISIONS: The bulletin date has been corrected from June to July, and group FL702-H was added.
Additional Repairs
Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a
vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns
before sale or delivery of a vehicle.
Owners may be liable for any progressive damage that results from failure to complete campaigns within a
reasonable time after receiving notification.
Work Instructions
Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a
completion sticker (Form WAR260).
Replacement Parts
Replacement parts are now available and can be obtained by ordering the kit number(s) listed below from your
facing Parts Distribution Center.
If our records show your dealership has ordered any vehicles involved in campaign number FL702, a list of the
customers and vehicle identification numbers will be available in OWL. Please refer to this list when ordering
parts for this recall.
Table 1 - Replacement Parts for FL702A-H
Campaign Number
FL702A & E
(51 VINs)
Kit Number
Part Description
Part Number
Qty. per Kit
14-19270-010
1 ea
F4HZ 3K506 C
1 ea
25-FL702-000
PUMP-POWER STEERING
MOUNTING GASKET-POWER
STEERING PUMP
ASSY-HOSE,POWER STEERING
HOSE-HYD,1.00 ID,HI TE,
CLAMP-LOOP,EPDM on STEEL,1IN DIA
CLAMP-HOSE,SGL,CUSH,1.
CLAMP-SPR STL, 1 INCH HOSE
BLANK COMPLETION STICKER
14-15614-424
48-25189-016
UMP S464G16
23-11357-125
23-12691-002
WAR260
1
1
4
1
2
1
Table 1, Continues on page 2.
Page 1
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Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Campaign Number
Kit Number
FL702B & F
(36 VINs)
Part Number
Qty. per Kit
14-19401-007
1 ea
F4HZ 3K506 C
1 ea
ELBOW-90,O-RING/HOSE
23-11858-216
1 ea
ASSY-HOSE,POWER STEERI
CLAMP-CUSHION DIA1 1/8
14-15614-424
23-11358-068
1 ea
1 ea
HOSE-HYD,1.00 ID,HI TE,
HOSE CLAMP
48-25189-016
IDL 5724
1 ea
2 ea
BLANK COMPLETION STICKER
WAR260
1 ea
HOSE-POWER STEERING,448"
WORM GEAR CLAMP
14-15614-448
IDL 5710
1 ea
2 ea
25-FL702-001
FL702C & G
(21 VINs)
Part Description
PUMP-STEERING,TRW,EV,
MOUNTING GASKET-POWER
STEERING PUMP
25-FL702-002
FL702A, B, C, E, F, & G
(108 VINs)
25-FL702-003
FL702D & H
(16 VINs)
No Kit. Order
individual part
number.
HOSE CLAMP
IDL 5724
2 ea
HOSE-HYD,1.00 ID,HI TE,
BLANK COMPLETION STICKER
48-25189-016
WAR260
1 ea
1 ea
HOSE-SHORT, STRAIGHT ENDS
HOSE-LONG, STRAIGHT END & 45°
ZFT 050122181601
ZFT 050122181701
1 ea
1 ea
HOSE-LONG, STRAIGHT END & 90°
HOSE-SHORT, STRAIGHT END & 90°
ZFT 050122181801
ZFT 050122181901
1 ea
1 ea
FITTING DIAM 4.12 TO 6.35 MM
ZFT 050133364101
1 ea
FITTING DIAM 4.12 TO 6.35 MM
ZFT 050133364101
1 ea
BLANK COMPLETION STICKER
WAR260
1 ea
Table 1, Continued from page 1.
Removed Parts
U.S. and Canadian Dealers, please follow Warranty Failed Parts Tracking shipping instructions for the
disposition of all removed parts. Export distributors, please destroy removed parts unless otherwise advised.
Labor Allowance
Table 2 - Labor Allowance
Campaign Number
Procedure
Time Allowed
(hours)
SRT Code
FL702A, B, E, & F
(ISX12 & ISX15)
Install pressure hoses, pump, and orifice
15.0
996-0975A
Install pressure hoses, pump, and orifice
13.0
996-0975B
Install orifice only
0.3
996-0975C
FL702C & G
(DD13)
FL702D & H
(ISX12)
Corrective Action
12-Repair Recall/Campaign
Table 2
IMPORTANT:When the Recall has been completed, locate the base completion label in the appropriate location on
the vehicle, and attach the red completion sticker provided in the recall kit (Form WAR260). If the vehicle does not
have a base completion label, clean a spot on the appropriate location of the vehicle and first attach the base
completion label (Form WAR259). If a recall kit is not required or there is no completion sticker in the kit, write the
recall number on a blank sticker and attach it to the base completion label.
Page 2
Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Claims for Credit
You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting
your claim through the Warranty system within 30 days of completing this campaign. Please reference the
following information in OWL:
• Claim type is Recall Campaign.
• In the Campaign field, enter the campaign number and appropriate group (e.g. FL702-A, FL702-B, etc.).
• In the Primary Failed Part field, enter 25-FL702-000.
• In the Parts section, enter the appropriate kit or part number(s) as shown in the Replacement Parts Table. A
maximum of $80 may be claim for power steering fluid.
• In the Labor section, enter the appropriate SRT from the Labor Allowance Table. Administrative time will be
included automatically as SRT 939-6010A for 0.4 hours for RVs.
• The VMRS Component Code is 015-005-003 and the Cause Code is A1 - Campaign.
• U.S. and Canada -- Reimbursement for Prior Repairs. When a customer asks about reimbursement,
please do the following:
• Accept the documentation of the previous repair.
• Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement.
(See the "Copy of Owner Letter" section of this bulletin for reimbursement guidelines.)
• Submit an OWL Recall Pre-Approval Request for a decision.
• Attach the documentation to the pre-approval request.
• If approved, submit a based on claim for the pre-approval.
• Reimburse the customer the appropriate amount.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the
campaign has not been previously completed. Also, check for a completion sticker prior to beginning work.
For questions, U.S. and Canadian dealers, contact the Warranty Campaigns Department from 7:00 a.m. to 4:00
p.m. Pacific Time, Monday through Friday, via Web inquiry at AccessFreightliner.com / Support / My Tickets
and Submit an Inquiry, or the Customer Assistance Center at (800) 385-4357, after normal business hours, if
you have any questions or need additional information. Export distributors, submit a Web inquiry or contact your
International Service Manager.
U.S. and Canadian Dealers: To return excess kit inventory related to this campaign, U.S. dealers must submit a
Parts Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing
PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number.
Export Distributors: Excess inventory is not returnable.
The letter notifying U.S. and Canadian vehicle owners is included for your reference.
Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code,
Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to
you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie
evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day
period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the
vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in
full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless
all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the
lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors
and retail outlets within five working days.
Page 3
Daimler Trucks
North America LLC
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Recall Campaign
Copy of Notice to Owners
Subject: FCCC XCP Chassis Power Steering Hoses
For the Notice to U.S. Customers: This notice is sent to you in accordance with the National Traffic and Motor
Vehicle Safety Act. For the Notice to Canadian Customers: This notice is sent to you in accordance with the
Canadian Motor Vehicle Safety Act.
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Freightliner Custom Chassis
Corporation, has decided that a defect which relates to motor vehicle safety exists on specific Freightliner
Custom Chassis XCP chassis vehicles manufactured April 26, 2013, through January 17, 2015.
On certain rear engine chassis, the power steering fluid temperature may exceed the hose material ratings. This
may lead to hose failure with a sudden loss of steering fluid and power assist. A sudden loss of steering assist
without warning could result in a vehicle crash.
To remedy the issue the suspect power steering hose will be replaced with one of higher temperature rating.
This is the second of two notices mailed regarding the subject of campaign FL702. The final repair is ready and
parts have been secured. Please contact an authorized Daimler Trucks North America dealer to arrange to
have the Recall performed and to ensure that parts are available at the dealership. To locate an authorized
dealer, search online at www.Daimler-TrucksNorthAmerica.com / Contact Us / Find a Dealer. The Recall will
take approximately half an hour to 15 hours, depending on the repair, and will be performed at no charge to
you.
You may be liable for any progressive damage that results from your failure to complete the Recall within a
reasonable time after receiving notification.
If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall
Notification, please return the notification to the Warranty Campaigns Department with any information you can
furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that
you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law
requires that you forward this notice to your distributors and retail outlets within five working days. If you have
paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement.
Please see the reverse side of this notice for details.
For the Notice to U.S. Customers: If you have questions about this Recall, please contact the Warranty
Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail
address [email protected], or the Customer Assistance Center at (800) 385-4357 after
normal business hours. If you are not able to have the defect remedied without charge and within a reasonable
time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration,
1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236
(TTY: 800-424-9153); or to http://www.safercar.gov. For the Notice to Canadian Customers: If you have
questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m.
to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address [email protected], or
the Customer Assistance Center at (800) 385-4357 after normal business hours.
We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle
safety.
WARRANTY CAMPAIGNS DEPARTMENT
Enclosure
Page 4
Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Reimbursement to Customers for Repairs
Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the
repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following
documentation must be presented to your dealer for consideration for reimbursement.
Please provide original or clear copies of all receipts, invoices, and repair orders that show
• The name and address of the person who paid for the repair
• The Vehicle Identification Number (VIN) of the vehicle that was repaired
• What problem occurred, what repair was done, when the repair was done
• Who repaired the vehicle
• The total cost of the repair expense that is being claimed
• Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt)
Reimbursement will be made by check from your Daimler Trucks North America LLC dealer.
Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter.
Page 5
Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
Work Instructions
Subject: FCCC XCP Chassis Power Steering Hoses
Models Affected:Specific Freightliner Custom Chassis XCP chassis manufactured April 26, 2013, through January 17, 2015.
REVISIONS: The bulletin date has been corrected from June to July, and group FL702-H was added.
Orifice and Hose Replacement Procedures
1. Check the base label (Form WAR259) for a completion sticker for FL702 (Form WAR260) indicating this work
has been done. The base label is usually located on the front wall under the dash. If a sticker is present, no work
is needed. If there is no sticker, proceed with the next step.
DANGER
When working on the vehicle, shut down the engine and set the parking brake. Before working under
the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Failure to
follow these steps could result in serious personal injury or death.
2. Park the vehicle on a level surface, shut down the engine, and set the parking brake.
3. Use the vehicle leveling jacks to create enough room to work under the vehicle.
4. Place jack stands under the frame rails to ensure the vehicle can not drop.
5. Remove the key from the ignition. Disconnect the battery cables, or if so equipped, turn the battery disconnect
switch to the OFF position.
6. Place a drain pan under the hydraulic pump.
IMPORTANT: Based on the type of engine installed in the vehicle, use the drawing number in Table 3 and
access the drawings in Shop Tech for this procedure.
7. At the bottom-right side of the engine, loosen the high-pressure power steering line from the hydraulic pump and
let the fluid drain into the pan.
Power Steering Drawings
Engine
Drawing Number
Cummins ISX12
Cummins ISX15
Detroit 13
D05-31933-000
D14-19321
D05-31770-000
D14-19222
D05-31793
Table 3, Power Steering Drawings
8. Place a drain pan under the power steering gear.
9. Loosen the power steering line at the bottom of the steering gear and let the fluid drain into the pan.
10. Remove the power steering return line at the bulkhead fitting.
11. Remove the orifice fitting at the bulkhead pass through and replace it with the new orifice. Tighten the fitting 42
lbf·ft (57 N·m).
Groups FL702A, B, C, E, and F: To avoid accidental loss, the kit orifice can be found attached to one of the new
pressure hoses. After the orifice is tightened, proceed to the next step.
Groups FL702D and G: After the orifice is tightened, reattach the power steering return line, then proceed to
step 30 on page 8.
Page 6
Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
12. Replace the power steering return hose with a new hose from the kit. Tighten the hose fittings 42 lbf·ft (57 N·m).
13. Remove the power steering hose from the rear of the power steering cylinder and replace it with a new hose
from the kit. Tighten the hose fittings 42 lbf·ft (57 N·m).
14. Remove the power steering hose from the front of the power steering cylinder and replace it with a new hose
from the kit. Tighten the hose fittings 42 lbf·ft (57 N·m).
15. Remove the power steering high-pressure line from the bulkhead pass through to the steering gear and replace
it with a new hose from the kit. Tighten the hose fittings 42 lbf·ft (57 N·m).
16. Remove the power steering line from the bulkhead pass through fitting.
17. At the bottom-right side of the engine, remove the power steering supply (suction) hose from the power steering
pump.
18. Remove the power steering (high-pressure) hose from the power steering pump.
19. Remove the two power steering pump mounting bolts from the engine mounting and remove the power steering
pump.
IMPORTANT: If the vehicle is equipped with a Detroit engine, do not remove the fittings.
20. Remove the fittings from the power steering pump. Keep the supply (suction) fitting for the new power steering
pump. Discard the high-pressure fitting and the power steering pump.
21. Remove and discard the power steering pump gasket from the mounting flange on the engine.
22. Install a new gasket on the mounting flange.
23. Install the fittings on the new power steering pump. Use the supply (suction) fitting removed earlier and tighten
it 67 to 74 lbf·ft (91 to 100 N·m). Use a new high-pressure fitting and tighten it 33 to 36 lbf·ft (45 to 49 N·m).
24. Using the mounting bolts, install the power steering pump. Tighten the mounting bolts 25 lbf·ft (34 N·m). See
Fig. 1 and Fig. 2.
1
3
2
20° ± 5°
2
15° ± 5°
3
1
03/17/2016
1. High-Pressure Fitting
2. Power Steering Pump
3. Suction Fitting
03/17/2016
f462273
1. Suction Fitting
2. Power Steering Pump
3. High-Pressure Fitting
Fig. 2, Steering Pump, Cummins ISX15
Fig. 1, Steering Pump, Cummins ISX12
Page 7
f462272
Daimler Trucks
North America LLC
Recall Campaign
July 2016
FL702A-H
NHTSA #16V-121
REVISED NOTICE
25. Remove the clamps and power steering hose from the power steering fluid reservoir and replace it with a new
hose and clamps.
26. At the front of the vehicle, use a male-to male JIC fitting and attach a new high-pressure supply line from the
kit to the old supply line to pull the new supply through later.
27. Starting at the front of the vehicle, follow the high-pressure hose to the rear, removing all tie straps that secure
the hose to the frame rail. Depending on the chassis model, it may be necessary to remove the Aqua Hot
reservoir and position it to the side in order to gain access to the rear compartment.
NOTICE
Do not use any power equipment to remove the hose. Doing so will damage the new hose. If there is
difficulty removing the hose, it may help to route the old hose toward the front of the vehicle over the
air bag.
NOTE: Due to the angle of pull on the hose, it is easier to remove the high-pressure hose from the back of the
vehicle. Always pull the hose in a straight line down the frame rail.
28. At the back of the vehicle, pull the old high-pressure hose through the frame rail until the new hose is in position
and can be attached to the new power steering pump.
29. Attach the new high-pressure hose on the new power steering pump and at the front bulkhead. Tighten the
fittings 42 lbf·ft (57 N·m). Ensure that all fittings and clamps are tight.
30. Connect the battery cables, or if so equipped, turn the battery disconnect switch to the ON position.
IMPORTANT: In order to avoid overflowing the power steering reservoir, fill only to the FULL HOT mark
on the dipstick.
31. Fill the power steering reservoir with Dexron III fluid to the FULL HOT mark on the dipstick. Start the engine,
then shut down the engine. Keep repeating the process until air is purged and the fluid level stops dropping.
Avoid running the power steering reservoir empty and foaming the fluid.
32. Once the fluid level stops dropping in the surge tank and the FULL COLD mark is maintained on the dipstick,
start the engine and let it run. While the engine is running, slowly turn the steering wheel from full right to full
left, purging any air that is trapped in the steering system.
33. Check all fittings, ensuring there are no leaks.
34. Remove the jack stands.
35. Clean a spot on the base label (Form WAR259). Write the recall number, FL702, on a blank red completion
sticker (Form WAR260) to indicate the work as been completed, and attach it to the base label.
Page 8