FL979 – Loss of Drive Power from Improperly Welded Axle – 2023-2024 Freightliner eCascadia

SEOCONTENT-START

DAIMLER TRUCK NORTH AMERICA | 4555 N CHANNEL AVE, PORTLAND, OR 97217 | 503.745.8000 | WWW.DAIMLERTRUCKNORTHAMERICA.COM 4875-9118-6798 v.1 001302/00009, 2:44 PM, 07/03/2023 Defect Information Report (Section 573.6) FL979 Date of Submission: 7/6/2023 Manufacturer: Daimler Truck North America LLC P.O. BOX 3849 Portland, Oregon 97208 Type of Report: X Safety Defect ⃝ Non-Compliance Vehicle Information Make Model Model Yr. Start Model Yr. End Prod. Begin Date Prod. End Date Freightliner eCascadia 2023 2024 1/19/2023 4/13/2023 Descriptive Information and Basis for Determination of Recall Population: The recall population includes MY 2023-2024 Freightliner eCascadia electric vehicles built with an e-axle(s) produced within a specific production period. These e-axles may have insufficiently welded planetary gear sets. Vehicles outside the population do not have planetary gear sets produced during the suspect time period. Number potentially involved: 82 Estimated percentage of involved with defect: 100% of the vehicles have the potential to have the defect. Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: The affected vehicles may be equipped with one or more e-axles, depending on the configuration of the vehicle. Within each e-axle assembly, a planetary gear set is located between the e-motor and the final drive. Due to a deviation in the supplier’s welding process during a specific time frame, certain planetary gear sets may have been insufficiently welded to the base plate and could fracture when exposed to high levels of torque and/or significant road DAIMLER TRUCK NORTH AMERICA | 4555 N CHANNEL AVE, PORTLAND, OR 97217 | 503.745.8000 | WWW.DAIMLERTRUCKNORTHAMERICA.COM 4875-9118-6798 v.1 001302/00009, 2:44 PM, 07/03/2023 surface vibrations. If a fracture occurs at the weld seam, the connection between the e-motor and the final drive can separate without warning to the driver. Describe the safety risk: If the connection between the e-motor and final drive separates, torque cannot be transferred to the drive wheels which can result in an undetectable and sudden loss of motive power and without the ability to restart the vehicle, thereby increasing the risk of a crash. Description of the Cause: Insufficient welding of planetary gear set to the baseplate. Identify any warning which can precede or occur: N/A If applicable, identify the manufacturer of the defective or noncompliant component.: Involved Components Component Name: E-axle Assembly Planetary gear set Component Description: Electric axle Component Part Number: D746381 Component Name: E-axle assembly Planetary gear set Component Description: Electric axle Component Part Number: D746383 Component Name: E-axle Assembly Planetary gear set Component Description: Electric axle Component Part Number: D746384 Supplier Identification: Mercedes-Benz Hedelfingen Component’s country of origin: Germany Business address: Am Ostkai 53, 70329 Stuttgart, Germany Business Contact Information: N/A First / Last Name: N/A Position: N/A Email: Phone: +49 1514 523892 DAIMLER TRUCK NORTH AMERICA | 4555 N CHANNEL AVE, PORTLAND, OR 97217 | 503.745.8000 | WWW.DAIMLERTRUCKNORTHAMERICA.COM 4875-9118-6798 v.1 001302/00009, 2:44 PM, 07/03/2023 Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: On February 20, 2023, DTNA conducted routine rough road testing of an e-Cascadia vehicle at its facility which involved driving the vehicle over cement risers and other unpaved and harsh road surfaces. During this testing, the truck experienced a loss of motive power while traveling at low speed. On March 2, 2023, DTNA conducted a tear down of the affected e-axle assembly where a fracture at the weld seam where the planetary gear attaches the baseplate was observed. The parts were sent for additional analysis. DTNA had opened an investigation to further analyze the issue, but on March 28, 2023, this investigation was closed on the basis that the failure had occurred during vehicle testing and under extreme road conditions that were not representative of real-world driving. Further, there were no reports of actual failures in the field (including after a review of vehicle telematics data) and it was believed that if a failure were to occur, the driver would have sufficient advanced warning to be able to respond. On May 4, 2023, DTNA opened a separate investigation after a report that the electric motor of an e-axle had decoupled, resulting in vehicle loss of forward movement. In this case, the instrument cluster did not display a telltale and did not generate a diagnostic trouble code for loss of forward movement which suggested the issue was electrical in nature. At the time there was no apparent connection between this topic and the fracture of the weld seam in the internal test vehicle. On June 7, 2023, DTNA was made aware of the first failure in the field potentially related to a fractured weld seam where the driver described the vehicle as struggling to move forward. Additional similar reports were received between June 7 – 28, 2023, where the drivers noted an inability to move forward and noting a gear pop. When the e-axle with the decoupled motor described above was later analyzed, it was discovered that the weld seam had separated in a manner similar to what was observed in the DTNA test truck. On June 30, 2023, DTNA decided to conduct a recall to address the issue. While the condition is primarily influenced by high torque, low speed maneuvers and severe road conditions, the possibility of a failure cannot be ruled out at higher speeds. DTNA has received 0 warranty claims and 3 field reports potentially related to this issue and is not aware of any accidents or injuries potentially related to this issue. DAIMLER TRUCK NORTH AMERICA | 4555 N CHANNEL AVE, PORTLAND, OR 97217 | 503.745.8000 | WWW.DAIMLERTRUCKNORTHAMERICA.COM 4875-9118-6798 v.1 001302/00009, 2:44 PM, 07/03/2023 Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. DTNA is preparing the remedy which is currently under development. Once available, the remedy will be performed free of charge by Daimler Truck North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Owners are directed to seek reimbursement for pre-recall notification repairs through authorized dealers. How Remedy Component Differs from Recalled Component: The remedy component will have planetary gear sets that are sufficiently welded to the baseplate. Identify How/When Recall Condition was Corrected in Production: The supplier made adjustments to the welding process so that parts produced after March 3, 2023, were sufficiently welded. Identify the Recall Schedule Describe the recall schedule for notifications.: Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Begin Date: 9/3/2023 Planned Dealer Notification End Date: 9/3/2023 Planned Owner Notification Begin Date: 9/3/2023 Planned Owner Notification End Date: 9/3/2023 Does DTNA plan to file inconsequentiality petition? ⃝ Yes X No Manufacturer’s identification code for this recall (if applicable): FL979 DTNA Representative; Sam Geser Sam Geser Manager, Compliance and Regulatory Affairs

**************************************************************************************************************

OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-467 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Daimler Trucks North America, LLC Submission Date : JUL 06, 2023 NHTSA Recall No. : 23V-467 Manufacturer Recall No. : FL979 Manufacturer Information : Manufacturer Name : Daimler Trucks North America, LLC Address : 4747 N. Channel Avenue Portland OR 97217-3849 Company phone : 800-745-8000 Population : Number of potentially involved : 82 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2023-2024 Freightliner eCascadia Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : 2-DOOR Power Train : HYBRID ELECTRIC Descriptive Information : The recall population includes MY 2023-2024 Freightliner eCascadia electric vehicles built with an e-axle(s) produced within a specific production period. These e-axles may have insufficiently welded planetary gear sets. Vehicles outside the population do not have planetary gear sets produced during the suspect time period. Production Dates : JAN 19, 2023 – APR 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : The affected vehicles may be equipped with one or more e-axles, depending on the configuration of the vehicle. Within each e-axle assembly, a planetary gear set is located between the e-motor and the final drive. Due to a deviation in the supplier’s welding process during a specific time frame, certain planetary gear sets may have been insufficiently welded to the base plate and could fracture when exposed to high levels of torque and/or significant road surface vibrations. If a fracture occurs at the weld seam, the connection between the emotor and the final drive can separate without warning to the driver. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the connection between the e-motor and final drive separates, torque cannot be transferred to the drive wheels which can result in an undetectable and sudden loss of motive power and without the ability to restart the vehicle, thereby increasing the risk of a crash. Description of the Cause : Insufficient welding of planetary gear set to the baseplate. Part 573 Safety Recall Report 23V-467 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : N/A Involved Components : Component Name 1 : E-axle Assembly Planetary gear set Component Description : Electric axle Component Part Number : D746381 Component Name 2 : E-axle assembly Planetary gear set Component Description : Electric axle Component Part Number : D746383 Component Name 3 : E-axle Assembly Planetary gear set Component Description : Electric axle Component Part Number : D746384 Supplier Identification : Component Manufacturer Name : Mercedes-Benz Hedelfingen Address : Am Ostkai 53 Stuttgart Foreign States 70329 Country : Germany Chronology : On February 20, 2023, DTNA conducted routine rough road testing of an e-Cascadia vehicle at its facility which involved driving the vehicle over cement risers and other unpaved and harsh road surfaces. During this testing, the truck experienced a loss of motive power while traveling at low speed. On March 2, 2023, DTNA conducted a tear down of the affected e-axle assembly where a fracture at the weld seam where the planetary gear attaches the baseplate was observed. The parts were sent for additional analysis. DTNA had opened an investigation to further analyze the issue, but on March 28, 2023, this investigation was Part 573 Safety Recall Report 23V-467 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 closed on the basis that the failure had occurred during vehicle testing and under extreme road conditions that were not representative of real-world driving. Further, there were no reports of actual failures in the field (including after a review of vehicle telematics data) and it was believed that if a failure were to occur, the driver would have sufficient advanced warning to be able to respond. On May 4, 2023, DTNA opened a separate investigation after a report that the electric motor of an e-axle had decoupled, resulting in vehicle loss of forward movement. In this case, the instrument cluster did not display a telltale and did not generate a diagnostic trouble code for loss of forward movement which suggested the issue was electrical in nature. At the time there was no apparent connection between this topic and the fracture of the weld seam in the internal test vehicle. On June 7, 2023, DTNA was made aware of the first failure in the field potentially related to a fractured weld seam where the driver described the vehicle as struggling to move forward. Additional similar reports were received between June 7 – 28, 2023, where the drivers noted an inability to move forward and noting a gear pop. When the e-axle with the decoupled motor described above was later analyzed, it was discovered that the weld… (see attachment for further information). Description of Remedy : Description of Remedy Program : DTNA is preparing the remedy which is currently under development. Once available, the remedy will be performed free of charge by Daimler Truck North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Owners are directed to seek reimbursement for pre-recall notification repairs through authorized dealers. How Remedy Component Differs from Recalled Component : The remedy component will have planetary gear sets that are sufficiently welded to the baseplate. Identify How/When Recall Condition was Corrected in Production : The supplier made adjustments to the welding process so that parts produced after March 3, 2023, were sufficiently welded. Recall Schedule : Description of Recall Schedule : Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Date : SEP 03, 2023 – SEP 03, 2023 Planned Owner Notification Date : SEP 03, 2023 – SEP 03, 2023 * NR – Not Reported

**************************************************************************************************************

**************************************************************************************************************

**************************************************************************************************************

**************************************************************************************************************

**************************************************************************************************************

SEOCONTENT-END