FL856 FCCC Motorhome Chassis Rear PDMs

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Defect Information Report
(Section 573.6)
FL-856
Date of Submission: August 7, 2020
Manufacturer: Daimler Trucks North America LLC
P.O. BOX 3849
Portland, Oregon 97208
Type of Report: X Safety Defect ⃝ Non-Compliance
Vehicle Information
Model Yr. Start: 2018 Model Yr. End: 2018
Make: Freightliner Custom Chassis Model: XBP Chassis
Model Yr. Start: 2018 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XBR Chassis
Model Yr. Start: 2017 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XBS Chassis
Model Yr. Start: 2016 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XCL Chassis
Model Yr. Start: 2016 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XCM Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCP Chassis
Model Yr. Start: 2016 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCR Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCS Chassis
Production Dates: Begin: 11/23/2015 End: 11/30/2018
Descriptive Information: Chassis receiving an inspection only repair from recall campaign FL-788 and additional chassis’ equipped with a certain PDM manufactured within the suspect dates.
Number potentially involved: 11,077 Estimated percentage of involve with defect: 100%
Defect / Noncompliance Description
For this Defect/Noncompliance:
Describe the defect or noncompliance: On certain FCCC XB and XC chassis’, during manufacturing of the rear mounted Power Distribution Module (PDM), which is a PDM unique to these chassis, the internal circuit board may be inadvertently subject to bending stresses which may, after a period of vehicle use, lead to intermittent open circuits, in which the rear marker, brake lights or left turn signal lights may not function.
Describe the safety risk: Brake lights not working correctly may not notify motorists of a braking event which may lead to an increase crash risk.
Identify any warning which can precede or occur: Inoperative exterior lights can be detected during a pre-trip inspection.
If applicable, identify the manufacture of the defective or noncompliant component.: Eaton Corporation
Involved Components
Component Name: Power Distribution Module
Component Description: Power Distribution Module
Component Part Number: A66-05172-000, A66-05172-001, A66-05172-002, A66-05172-004,
A66-05172-005, A66-05172-006, A66-05172-008, A66-05172-009
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.: June 18, 2020, NHTSA notified DTNA of one vehicle owner questionnaire (VOQ) and two field complaints that may be related to FL-788. DTNA opened an investigation to reevaluate the scope of FL-788. Complaint reviews, study of changes to supplier manufacturing and inspection processes revealed additional vehicles manufactured after the FL-788 population bookend June 29, 2018. Further, the voltage test used for a portion of the recall FL-788 population may not be adequate in identifying a failed PDM. July 7, 2020, DTNA, with an abundance of caution, decided to initiate a voluntary recall to campaign vehicles that received an inspection-only remedy and campaign vehicles not initially captured in the original FL-788 population. August 7, 2020, DTNA has removed additional suspect vehicles that received a PDM replacement.
Identify the Remedy
Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement.: Vehicles will receive a new rear Power Distribution Module (PDM). Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter.
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: 09/10/2020
Planned Dealer Notification End Date: 09/10/2020
Planned Owner Notification Begin Date: 09/10/2020
Planned Owner Notification End Date: 09/10/2020
Manufacture’s identification code for this recall (if applicable): FL-856
DTNA Representative;
Daimler Trucks North America
Larissa Stoffels
Executive Manager, Vehicle Safety
Compliance and Regulatory Affairs

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Amended Defect Information Report
(Section 573.6)
FL-856
Date of Submission: June 17, 2021
Manufacturer: Daimler Trucks North America LLC
P.O. BOX 3849
Portland, Oregon 97208
Type of Report: X Safety Defect ⃝ Non-Compliance
Vehicle Information
Model Yr. Start: 2018 Model Yr. End: 2018
Make: Freightliner Custom Chassis Model: XBP Chassis
Model Yr. Start: 2017 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XBR Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XBS Chassis
Model Yr. Start: 2016 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XCL Chassis
Model Yr. Start: 2016 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCM Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCP Chassis
Model Yr. Start: 2016 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCR Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCS Chassis
Production Dates: Begin: 11/23/2015 End: 06/03/2019
Descriptive Information: Chassis receiving a PDM with serial 18106398 or lower from FL-788 and additional chassis equipped with a certain PDM manufactured within the suspect dates.
Number potentially involved: 16,776 Estimated percentage of involve with defect: 100%
Defect / Noncompliance Description
For this Defect/Noncompliance:
Describe the defect or noncompliance: On certain FCCC XB and XC chassis, during manufacturing of the rear mounted Power Distribution Module (PDM), which is a PDM unique to these chassis, the internal circuit board may be inadvertently subject to bending stresses which may, after a period of vehicle use, lead to intermittent open circuits, in which the rear marker, brake lights or left turn signal lights may not function.
Describe the safety risk: Brake lights not working correctly may not notify motorists of a braking event which may lead to an increase crash risk.
Identify any warning which can precede or occur: Inoperative exterior lights can be detected during a pre-trip inspection.
If applicable, identify the manufacture of the defective or noncompliant component.: Eaton Corporation
Involved Components
Component Name: Power Distribution Module
Component Description: Power Distribution Module
Component Part Number: A66-05172-000, A66-05172-001, A66-05172-002, A66-05172-004,
A66-05172-005, A66-05172-006, A66-05172-008, A66-05172-009, A66-05172-010, A66-05172-011
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision.: June 18, 2020, NHTSA notified DTNA of one vehicle owner questionnaire (VOQ) and two field complaints that may be related to FL-788. DTNA opened an investigation to reevaluate the scope of FL-788. Complaint reviews, study of changes to supplier manufacturing and inspection processes revealed additional vehicles manufactured after the FL-788 population bookend June 29, 2018. Further, the voltage test used for a portion of the recall FL-788 population may not be adequate in identifying a failed PDM. July 7, 2020, DTNA, with an abundance of caution, decided to initiate a voluntary recall to campaign vehicles that received an inspection-only remedy and campaign vehicles not initially captured in the original FL-788 population. August 7, 2020, DTNA has removed additional suspect vehicles that received a PDM replacement. July – October 2020, DTNA continued to receive returned parts from the field for supplier analysis. October 2020, the supplier proposed expanding the FL856 population, reviewed the supplier proposal and performed a statistical analysis on parts returned to expand campaign FL-856 population to June 2019. October 30, 2020 with an abundance of caution, decided to expand a voluntary recall to campaign additional vehicles that may have received a PDM manufactured before November 30, 2018 either in the standard manufacturing process or in the recall remedy for FL-788.
March 2021, DTNA is accumulating parts needed for this recall and due to supply constraints, we do not have the minimum available to release the recall at this time. DTNA is working with our supplier to get parts that are needed for release. As DTNA informed NHTSA on June 10, 2021, DTNA anticipates promptly sending final owner letters when NHTSA approves the letter submitted to the agency on June 2, 2021 and when parts become available.
Identify the Remedy
Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement.: Vehicles will be inspected and receive a new rear Power Distribution Module (PDM) as needed. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter.
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: 09/03/2020
Planned Dealer Notification End Date: 09/30/2021
Planned Owner Notification Begin Date: 09/03/2020
Planned Owner Notification End Date: 09/30/2021
Manufacture’s identification code for this recall (if applicable): FL-856
DTNA Representative;
Daimler Trucks North America
Larissa Stoffels
Executive Manager, Vehicle Safety
Compliance and Regulatory Affairs

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

Amended Defect Information Report
(Section 573.6)
FL-856
Date of Submission: March 19, 2021
Manufacturer: Daimler Trucks North America LLC
P.O. BOX 3849
Portland, Oregon 97208
Type of Report: X Safety Defect ⃝ Non-Compliance
Vehicle Information
Model Yr. Start: 2018 Model Yr. End: 2018
Make: Freightliner Custom Chassis Model: XBP Chassis
Model Yr. Start: 2017 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XBR Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XBS Chassis
Model Yr. Start: 2016 Model Yr. End: 2019
Make: Freightliner Custom Chassis Model: XCL Chassis
Model Yr. Start: 2016 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCM Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCP Chassis
Model Yr. Start: 2016 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCR Chassis
Model Yr. Start: 2017 Model Yr. End: 2020
Make: Freightliner Custom Chassis Model: XCS Chassis
Production Dates: Begin: 11/23/2015 End: 06/03/2019
Descriptive Information: Chassis receiving a PDM with serial 18106398 or lower from FL-788 and
additional chassis equipped with a certain PDM manufactured within the suspect dates.
Number potentially involved: 16,776 Estimated percentage of involve with defect: 100%
Defect / Noncompliance Description
For this Defect/Noncompliance:
Describe the defect or noncompliance: On certain FCCC XB and XC chassis, during manufacturing of
the rear mounted Power Distribution Module (PDM), which is a PDM unique to these chassis, the internal
circuit board may be inadvertently subject to bending stresses which may, after a period of vehicle use,
lead to intermittent open circuits, in which the rear marker, brake lights or left turn signal lights may not
function.
Describe the safety risk: Brake lights not working correctly may not notify motorists of a braking event
which may lead to an increase crash risk.
Identify any warning which can precede or occur: Inoperative exterior lights can be detected during
a pre-trip inspection.
If applicable, identify the manufacture of the defective or noncompliant component.: Eaton
Corporation
Involved Components
Component Name: Power Distribution Module
Component Description: Power Distribution Module
Component Part Number: A66-05172-000, A66-05172-001, A66-05172-002, A66-05172-004,
A66-05172-005, A66-05172-006, A66-05172-008, A66-05172-009, A66-05172-010, A66-05172-011
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.: June 18, 2020, NHTSA notified DTNA of one vehicle owner questionnaire
(VOQ) and two field complaints that may be related to FL-788. DTNA opened an investigation to
reevaluate the scope of FL-788. Complaint reviews, study of changes to supplier manufacturing and
inspection processes revealed additional vehicles manufactured after the FL-788 population bookend
June 29, 2018. Further, the voltage test used for a portion of the recall FL-788 population may not be
adequate in identifying a failed PDM. July 7, 2020, DTNA, with an abundance of caution, decided to
initiate a voluntary recall to campaign vehicles that received an inspection-only remedy and campaign
vehicles not initially captured in the original FL-788 population. August 7, 2020, DTNA has removed
additional suspect vehicles that received a PDM replacement. July – October 2020, DTNA continued to
receive returned parts from the field for supplier analysis. October 2020, the supplier proposed
expanding the FL856 population, reviewed the supplier proposal and performed a statistical analysis on
parts returned to expand campaign FL-856 population to June 2019. October 30, 2020 with an
abundance of caution, decided to expand a voluntary recall to campaign additional vehicles that may
have received a PDM manufactured before November 30, 2019 either in the standard manufacturing
process or in the recall remedy for FL-788.
March 2021, DTNA is accumulating parts needed for this recall and due to supply constraints, we do not
have the minimum available to release the recall at this time. DTNA is working with our supplier to get
parts that are needed for release.
Identify the Remedy
Describe the defect/noncompliance remedy program, including the manufacture’s plan for
reimbursement.: Vehicles will be inspected and receive a new rear Power Distribution Module (PDM)
as needed. Repairs will be performed by Daimler Trucks North America authorized service facilities.
Details of the reimbursement plan will be included in the owner’s notification letter.
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: 01/03/2021
Planned Dealer Notification End Date: 01/03/2021
Planned Owner Notification Begin Date: 01/03/2021
Planned Owner Notification End Date: 01/03/2021
Manufacture’s identification code for this recall (if applicable): FL-856
DTNA Representative;
Daimler Trucks North America
Larissa Stoffels
Executive Manager, Vehicle Safety
Compliance and Regulatory Affairs

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

REF #:
ICI20-037
Effective:
11/18/20
Release:
11/18/20
SUBJECT:
FL856 – Interim Recall Notice
This letter is to inform you that an Interim Recall Notice was sent to affected customers for upcoming recall FL856 ~ FCCC Motorhome Chassis Rear PDMs. The interim notice will begin mailing on November 20, 2020 and is attached to the back of this letter for your reference.
This notice is for informational purposes only. There is no action for customers or dealers to take at this time. If customers inquire, please refer them to the Interim Recall Notice and let them know the recall will begin when all preparations are completed.
If you have questions or need further information, contact the Warranty Campaigns Department by submitting an inquiry through the WSC Link on DTNAConnect.
WARRANTY CAMPAIGNS DEPARTMENT
P.O. Box 4090
800-547-0712
Portland, Oregon 97208-4090
ATTENTION: Dealer Principal, Warranty Manager, Service Manager, Parts Manager
Freightliner Dealers – U.S. and Canada
Western Star and Sterling Dealers – U.S. and Canada
FCCC Dealers – U.S. and Canada
Thomas Built Buses Dealers – U.S. and Canada
Direct Warranty Customers – U.S. and Canada
Detroit Diesel Distributors
Export Distributors

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