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September 18, 2020 NHTSA CAMPAIGN NUMBER: 20V567000
Brake Lights Stay Illuminated After Pedal Release
If the brake lights remain illuminated, drivers may be unaware when the truck is actually slowing or stopping, increasing the risk of a crash.
NHTSA Campaign Number: 20V567
Manufacturer Daimler Trucks North America LLC
Components EXTERIOR LIGHTING
Potential Number of Units Affected 128,269
Summary
Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2021 Cascadia P4 vehicles. The brake lights may remain illuminated after the brake pedal has been released.
Remedy
DTNA will notify owners, and dealers will replace the 3-pin brake pressure switch with a 2-pin brake pressure switch along with a jumper harness, free of charge. DTNA issued owners an interim notification on November 17, 2020. The remedy is expected to be available in December 2021. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-863.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Check for Daimler Trucks North America Recalls


November 2021
FL863A (Final)
INT FL863-01 (Interim)
NHTSA #20V-567
Transport Canada #2020-444
Subject: Freightliner
Cascadia Brake Light Illumination
Models Affected: Specific model year 2017-2021 Freightliner
Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain brake light pressure switch.
General Information
Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner
Trucks Division, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.
On certain vehicles, the brake lights may remain on after release of the brake pedal, presenting inaccurate information to vehicles which are following, potentially leading to an increased risk of a crash.
Vehicles in FL863A are built with Detroit engines and will have the 3-pin switch replaced with a 2-pin switch and a jumper harness. This is the final repair and a sticker must be placed in the door upon completion.
Vehicles in INT FL863-01 are built with Cummins engines and will have a 3-pin switch replaced with a new 3-pin switch as an interim repair; DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. Owners in INT FL863-01 will receive a final notice when the final repair for Cummins
engines is available.
There are approximately 145,444 vehicles involved in this campaign.
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 Final FL863 campaign, check the vehicle for a completion sticker (Form WAR260). Prior to performing the INT FL863 check the OWL Coverage screen for completion.
Replacement Parts
Replacement parts are now available and can be obtained by ordering the part number(s) listed below from your facing Parts Distribution Center.
If our records show your dealership has ordered any vehicle(s) involved in campaign number FL863, a list of the customers and vehicle identification numbers will be available on DTNAConnect. Please refer to this list when ordering parts for this recall.
Work Instructions
Vehicles in FL863A will have the 3-pin switch replaced with a 2-pin switch and a jumper harness. This is the final repair and a sticker must be placed in the door upon completion.
Vehicles in INT FL863-01 will have a 3-pin switch replaced with a new 3-pin switch as an interim repair; DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work.
Pressure Switch Replacement
1. For vehicles in FL863A, check the base label (Form WAR259) for a completion sticker (Form WAR260) indicating this work has been done. The base label is usually located on the passenger side door, about 12inches (30cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step.
For vehicles in INT FL863-01, please check the OWL coverage screen indicating this work has been completed.
2. Park the vehicle, apply the parking brakes, and shut down the engine. Chock the tires.
3. Remove the lower steering column and throttle cover dash panels. If instructions are needed, see the New Cascadia Workshop Manual Section 60.06.100 Dash Panels Removal and Installation.
NOTE: Depending on the vehicle build date, the 3-pin brake light pressure switch may be in one of two locations on the pass-through switch manifold. See Fig. 1.
4. Disconnect and remove the 3-pin brake light pressure switch.
5. Install the new pressure switch.
Vehicles in FL863A, continue to next step.
Vehicles in INT FL863-01, go to step 5.3.
5.1 Install the 2-pin pressure switch on vehicles in FL863A. Torque the switch 7 to 9 lbf·ft (9.5 to 12 N.m) See Fig. 2.
5.2 Install the jumper harness (see Fig. 3) onto the dash connector (see Fig. 4) and then connect it to the new 2-pin brake light pressure switch. Continue to step 6.
5.3 Install the new 3-pin pressure switch on vehicles in INT FL863-01. Torque the switch 7 to 9 lbf·ft (9.5 to 12 N·m). See Fig. 2. Then reconnect the existing connector.
6. Install the lower steering column and throttle cover dash panels. If instructions are needed, see the New Cascadia Workshop Manual Section 60.06.100 Dash Panels Removal and Installation.
7. Vehicles in INT FL863-01, DO NOT place a sticker in the door. File the INT FL863-01 recall claim immediately after completion of work.
Vehicles in FL863A, clean a spot on the base label (Form WAR259). Write the recall number, FL863-A, on a blank red completion sticker (Form WAR260), and attach it to the base label to indicate this recall has been completed.
Chronology :
In or about March 2019, DTNA received a single field report of brake lights remaining on after the brake pedal was released. DTNA’s analysis, given the information reasonably available, did not indicate an unreasonable risk to safety.
In or about June 2019, DTNA received second field report of brake lights remaining on, along with complaints of the cruise control being rendered inoperative due to brake pressure switch malfunction.
As a result, in or about July 2019, DTNA commenced an investigation of the matter. DTNA also communicated with NHTSA Office of Defects Investigation (ODI) during this time period regarding its investigation, including making verbal updates and presentations to ODI staff. During this time period, DTNA’s analysis, again given the information reasonably available, continued to not indicate an unreasonable risk to safety.
In or about January 2020, DTNA’s investigation commenced an extensive warranty review. During the pendency of that warranty review, in or about February 2020, DTNA received two additional field reports of brake lights remaining due to brake pressure switch malfunction.
Following its analysis, in or about March 2020, DTNA reasonably determined that there was no unreasonable risk to safety within the meaning of the Safety Act and applicable law. In or about May 2020 – July 2020, out of an abundance of caution, DTNA analyzed failed switches for functional and durability testing.
DTNA’s analysis identified that the pressure switch was mechanically operating as per standard operating requirements, and did not otherwise call into question DTNA’s analysis to date.
In or about August – early September 2020, conducted a supplemental data review to check for the potential for late in the life failures. DTNA’s new data revealed that 24MIS and 36MIS failure rate was high.
As a result, on September 14, 2020, out of an abundance of caution, DTNA reasonably decided to conduct a voluntary recall as set forth in this report.
5 Affected Products
Vehicle
MAKE | MODEL | YEAR |
FREIGHTLINER![]() | CASCADIA | 2017-2021 |
13 Associated Documents
Miscellaneous Document- Amended Defect Information Report
RMISC-20V567-5404.pdf 813.984KB
Recall 573 Report- Amendment 1
RCLRPT-20V567-4950.PDF 214.03KB
Miscellaneous Document- Amended 573 Defect Information Report
RMISC-20V567-0033.pdf 719.578KB
Recall Acknowledgement
RCAK-20V567-9188.pdf 244.815KB
Miscellaneous Document- Defect Information Report
RMISC-20V567-3584.pdf 720.351KB
Defect Notice 573 Report
RCLRPT-20V567-5014.PDF 213.971KB
Manufacturer Notices(to Dealers,etc)
Interim Owner Notification Letter(Part 577)
RIONL-20V567-5683.pdf 48.764KB
Miscellaneous Document- Amended Defect Information Report
RMISC-20V567-5814.pdf 814.594KB
Recall 573 Report- Amendment 2
RCLRPT-20V567-1094.PDF 214.112KB
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-20V567-4307.pdf 162.89KB
Manufacturer Notices(to Dealers,etc)
RCMN-20V567-5266.pdf 245.392KB
ISSUED Owner Notification Letter(Part 577)
RCONL-20V567-5943.pdf 143.386KB
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Defect Information Report (Section 573.6) FL-863 Date of Submission: Sept 18, 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: 2017 Model Yr. End: 2021 Make: Freightliner Model: Cascadia P4 Production Dates: Begin: 03/08/2016 End: 01/03/2020 Descriptive Information: Vehicles built with a certain pressure switch within the above referenced build dates. Number potentially involved: 128,269 Estimated percentage involved with defect: 5% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the brake lights may remain on after release of brake pedal. If a noncompliance, provide the applicable FMVSS Describe the safety risk: Brake lights remaining on may prevent accurate communication to following vehicles. While the brakes lights are on, with additional service brake application, the intensity in brake lights would not change and would not signal to other motorists the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: In or about March 2019, DTNA received a single field report of brake lights remaining on after the brake pedal was released. As a result, DTNA reviewed relevant warranty rate data to assess the matter. DTNA’s analysis, given the information reasonably available, did not indicate an unreasonable risk to safety. In or about June 2019, DTNA received second field report of brake lights remaining on, along with complaints of the cruise control being rendered inoperative due to brake pressure switch malfunction. As a result, in or about July 2019, DTNA commenced an investigation of the matter. DTNA also communicated with NHTSA Office of Defects Investigation (ODI) during this time period regarding its investigation, including making verbal updates and presentations to ODI staff. During this time period, DTNA’s analysis, again given the information reasonably available, continued to not indicate an unreasonable risk to safety. In or about January 2020, DTNA’s investigation commenced an extensive warranty review. During the pendency of that warranty review, in or about February 2020, DTNA received two additional field reports of brake lights remaining due to brake pressure switch malfunction. Following its analysis, in or about March 2020, DTNA reasonably determined that there was no unreasonable risk to safety within the meaning of the Safety Act and applicable law. In or about May 2020 – July 2020, out of an abundance of caution, DTNA analyzed failed switches for functional and durability testing. DTNA’s analysis identified that the pressure switch was mechanically operating as per standard operating requirements, and did not otherwise call into question DTNA’s analysis to date. In or about August – early September 2020, conducted a supplemental data review to check for the potential for late in the life failures. DTNA’s new data revealed that 24MIS and 36MIS failure rate was high. As a result, on September 14, 2020, out of an abundance of caution, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject 3-pin brake pressure switch on the affected vehicles will be replaced with 2-pin brake pressure switch along with a jumper harness. Customer notification will be done by first class mail using Daimler Trucks North America records to determine the customers affected. Copies of the reimbursement plan will be submitted as a supplemental report when available. 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: 11/16/2020 Planned Dealer Notification End Date: 11/16/2020 Planned Owner Notification Begin Date: 11/16/2020 Planned Owner Notification End Date: 11/16/2020 Manufacture’s identification code for this recall (if applicable): FL-863 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs
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Amended Defect Information Report (Section 573.6) FL-863 Date of Submission: November 1, 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: 2017 Model Yr. End: 2021 Make: Freightliner Model: Cascadia P4 Production Dates: Begin: 03/08/2016 End: 01/03/2020 Descriptive Information: Vehicles built with a certain pressure switch within the above referenced build dates. Number potentially involved: 128,269 Estimated percentage involved with defect: 5% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the brake lights may remain on after release of brake pedal. If a noncompliance, provide the applicable FMVSS Describe the safety risk: Brake lights remaining on may prevent accurate communication to following vehicles. While the brakes lights are on, with additional service brake application, the intensity in brake lights would not change and would not signal to other motorists the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. Supplier Identification: Component Manufacturer: Name: Honeywell Address: 12484 Collection Center Dr Chicago, IL 606930124 Country: Unites States Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: In or about March 2019, DTNA received a single field report of brake lights remaining on after the brake pedal was released. As a result, DTNA reviewed relevant warranty rate data to assess the matter. DTNA’s analysis, given the information reasonably available, did not indicate an unreasonable risk to safety. In or about June 2019, DTNA received second field report of brake lights remaining on, along with complaints of the cruise control being rendered inoperative due to brake pressure switch malfunction. As a result, in or about July 2019, DTNA commenced an investigation of the matter. DTNA also communicated with NHTSA Office of Defects Investigation (ODI) during this time period regarding its investigation, including making verbal updates and presentations to ODI staff. During this time period, DTNA’s analysis, again given the information reasonably available, continued to not indicate an unreasonable risk to safety. In or about January 2020, DTNA’s investigation commenced an extensive warranty review. During the pendency of that warranty review, in or about February 2020, DTNA received two additional field reports of brake lights remaining due to brake pressure switch malfunction. Following its analysis, in or about March 2020, DTNA reasonably determined that there was no unreasonable risk to safety within the meaning of the Safety Act and applicable law. In or about May 2020 – July 2020, out of an abundance of caution, DTNA analyzed failed switches for functional and durability testing. DTNA’s analysis identified that the pressure switch was mechanically operating as per standard operating requirements, and did not otherwise call into question DTNA’s analysis to date. In or about August – early September 2020, conducted a supplemental data review to check for the potential for late in the life failures. DTNA’s new data revealed that 24MIS and 36MIS failure rate was high. As a result, on September 14, 2020, out of an abundance of caution, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. April 1, 2020, DTNA added supplier identification information. As DTNA informed NHTSA on June 10, 2021, DTNA anticipates sending the owner letters in September 2021 or December 2021, for the Detroit engine configurations and the Cummins engine configurations respectively, based on the availability of parts. November 1, 2021, due to parts availability, the recall release has been delayed to launch in mid-November 2021. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject 3-pin brake pressure switch on the affected vehicles built with Detroit engines will be replaced with 2-pin brake pressure switch along with a jumper harness. Furthermore, the subject 3-pin brake pressure switch on the affected vehicles built with Cummins engines will be replaced with 2-pin brake pressure switch along with a jumper harness and a software installation. Customer notification will be done by first class mail using Daimler Trucks North America records to determine the customers affected. Copies of the reimbursement plan will be submitted as a supplemental report when available. 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: 11/16/2021 Planned Dealer Notification End Date: 09/30/2021 and 12/31/2021 Planned Owner Notification Begin Date: 11/16/2021 Planned Owner Notification End Date: 09/30/2021 and 12/31/2021 Manufacture’s identification code for this recall (if applicable): FL-863 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs
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Amended Defect Information Report (Section 573.6) FL-863 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: 2017 Model Yr. End: 2021 Make: Freightliner Model: Cascadia P4 Production Dates: Begin: 03/08/2016 End: 01/03/2020 Descriptive Information: Vehicles built with a certain pressure switch within the above referenced build dates. Number potentially involved: 128,269 Estimated percentage involved with defect: 5% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the brake lights may remain on after release of brake pedal. If a noncompliance, provide the applicable FMVSS Describe the safety risk: Brake lights remaining on may prevent accurate communication to following vehicles. While the brakes lights are on, with additional service brake application, the intensity in brake lights would not change and would not signal to other motorists the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. Supplier Identification: Component Manufacturer: Name: Honeywell Address: 12484 Collection Center Dr Chicago, IL 606930124 Country: Unites States Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: In or about March 2019, DTNA received a single field report of brake lights remaining on after the brake pedal was released. As a result, DTNA reviewed relevant warranty rate data to assess the matter. DTNA’s analysis, given the information reasonably available, did not indicate an unreasonable risk to safety. In or about June 2019, DTNA received second field report of brake lights remaining on, along with complaints of the cruise control being rendered inoperative due to brake pressure switch malfunction. As a result, in or about July 2019, DTNA commenced an investigation of the matter. DTNA also communicated with NHTSA Office of Defects Investigation (ODI) during this time period regarding its investigation, including making verbal updates and presentations to ODI staff. During this time period, DTNA’s analysis, again given the information reasonably available, continued to not indicate an unreasonable risk to safety. In or about January 2020, DTNA’s investigation commenced an extensive warranty review. During the pendency of that warranty review, in or about February 2020, DTNA received two additional field reports of brake lights remaining due to brake pressure switch malfunction. Following its analysis, in or about March 2020, DTNA reasonably determined that there was no unreasonable risk to safety within the meaning of the Safety Act and applicable law. In or about May 2020 – July 2020, out of an abundance of caution, DTNA analyzed failed switches for functional and durability testing. DTNA’s analysis identified that the pressure switch was mechanically operating as per standard operating requirements, and did not otherwise call into question DTNA’s analysis to date. In or about August – early September 2020, conducted a supplemental data review to check for the potential for late in the life failures. DTNA’s new data revealed that 24MIS and 36MIS failure rate was high. As a result, on September 14, 2020, out of an abundance of caution, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. April 1, 2020, DTNA added supplier identification information. As DTNA informed NHTSA on June 10, 2021, DTNA anticipates sending the owner letters in September 2021 or December 2021, for the Detroit engine configurations and the Cummins engine configurations respectively, based on the availability of parts. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject 3-pin brake pressure switch on the affected vehicles built with Detroit engines will be replaced with 2-pin brake pressure switch along with a jumper harness. Furthermore, the subject 3-pin brake pressure switch on the affected vehicles built with Cummins engines will be replaced with 2-pin brake pressure switch along with a jumper harness and a software installation. Customer notification will be done by first class mail using Daimler Trucks North America records to determine the customers affected. Copies of the reimbursement plan will be submitted as a supplemental report when available. 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: 11/16/2020 Planned Dealer Notification End Date: 09/30/2021 and 12/31/2021 Planned Owner Notification Begin Date: 11/16/2020 Planned Owner Notification End Date: 09/30/2021 and 12/31/2021 Manufacture’s identification code for this recall (if applicable): FL-863 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs
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Amended Defect Information Report (Section 573.6) FL-863 Date of Submission: April 6, 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: 2017 Model Yr. End: 2021 Make: Freightliner Model: Cascadia P4 Production Dates: Begin: 03/08/2016 End: 01/03/2020 Descriptive Information: Vehicles built with a certain pressure switch within the above referenced build dates. Number potentially involved: 128,269 Estimated percentage involved with defect: 5% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the brake lights may remain on after release of brake pedal. If a noncompliance, provide the applicable FMVSS Describe the safety risk: Brake lights remaining on may prevent accurate communication to following vehicles. While the brakes lights are on, with additional service brake application, the intensity in brake lights would not change and would not signal to other motorists the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. Supplier Identification: Component Manufacturer: Name: Honeywell Address: 12484 Collection Center Dr Chicago, IL 606930124 Country: Unites States Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: In or about March 2019, DTNA received a single field report of brake lights remaining on after the brake pedal was released. As a result, DTNA reviewed relevant warranty rate data to assess the matter. DTNA’s analysis, given the information reasonably available, did not indicate an unreasonable risk to safety. In or about June 2019, DTNA received second field report of brake lights remaining on, along with complaints of the cruise control being rendered inoperative due to brake pressure switch malfunction. As a result, in or about July 2019, DTNA commenced an investigation of the matter. DTNA also communicated with NHTSA Office of Defects Investigation (ODI) during this time period regarding its investigation, including making verbal updates and presentations to ODI staff. During this time period, DTNA’s analysis, again given the information reasonably available, continued to not indicate an unreasonable risk to safety. In or about January 2020, DTNA’s investigation commenced an extensive warranty review. During the pendency of that warranty review, in or about February 2020, DTNA received two additional field reports of brake lights remaining due to brake pressure switch malfunction. Following its analysis, in or about March 2020, DTNA reasonably determined that there was no unreasonable risk to safety within the meaning of the Safety Act and applicable law. In or about May 2020 – July 2020, out of an abundance of caution, DTNA analyzed failed switches for functional and durability testing. DTNA’s analysis identified that the pressure switch was mechanically operating as per standard operating requirements, and did not otherwise call into question DTNA’s analysis to date. In or about August – early September 2020, conducted a supplemental data review to check for the potential for late in the life failures. DTNA’s new data revealed that 24MIS and 36MIS failure rate was high. As a result, on September 14, 2020, out of an abundance of caution, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. April 1, 2020, DTNA added supplier identification information. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject 3-pin brake pressure switch on the affected vehicles will be replaced with 2-pin brake pressure switch along with a jumper harness. Customer notification will be done by first class mail using Daimler Trucks North America records to determine the customers affected. Copies of the reimbursement plan will be submitted as a supplemental report when available. 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: 11/16/2020 Planned Dealer Notification End Date: 11/16/2020 Planned Owner Notification Begin Date: 11/16/2020 Planned Owner Notification End Date: 11/16/2020 Manufacture’s identification code for this recall (if applicable): FL-863 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs
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Daimler Trucks North America LLC November 2020 FL863 Interim Recall Notice NHTSA #20V-567 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Freightliner Cascadia Brake Light Illumination This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, has decided that a defect which relates to motor vehicle safety exists on specific Model Year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain pressure switch. On certain vehicles, the brake lights may remain on after release of the brake pedal, which may prevent accurate communication to following vehicles. While the brake lights are on, with additional service brake application, the intensity of brake lights would not change and would not signal to other motorist the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. This is the first of two notices you will receive regarding this subject. This letter is to inform you of an upcoming Recall to correct the issue noted above. Daimler Trucks is currently validating the repair. There is no action for you to take at this time. The second notice will inform you when the final remedy is available. When you receive the second notice, please contact your authorized Daimler Trucks North America dealer to schedule the Recall for your vehicle. 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 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 DTNA.Warranty.Campaigns@Daimler.com. For other concerns, you may contact the Customer Assistance Center at (800) 385-4357. 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 go to https://www.safercar.gov. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone
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Daimler Trucks North America LLC November 2021 INT FL863-01 Interim Repair Recall Notice NHTSA #20V-567 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Freightliner Cascadia Brake Light Illumination This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, has decided that a defect which relates to motor vehicle safety exists on specific Model Year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain pressure switch. On certain vehicles, the brake lights may remain on after release of the brake pedal, which may prevent accurate communication to following vehicles, potentially leading to an increased risk of a crash. The final repair on Cummins engines requires a software update that is currently in development. In the interim, the 3-pin brake pressure switch will be replaced with a new 3-pin brake pressure switch. Repairs will be performed by Daimler Trucks North America authorized service facilities. Please contact an authorized Daimler Trucks North America dealer to arrange to have this repair performed and to ensure that parts are available at the dealership. To locate an authorized dealer, search online at www.Daimler-TrucksNorth America.com / Contact (scroll to the bottom) / Locate a Dealer (scroll to the bottom). This repair will take approximately one hour and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at this URL: https://dtna-dlrinfo.prd.freightliner.com:48518/VinLookup/vin-module/getVinLookupPage. A third notice will inform you when the final remedy is available. When you receive the third notice, please contact your authorized Daimler Trucks North America dealer to schedule the final Recall for your vehicle. All vehicles that have the interim repair performed will also require the final repair. 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 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 DTNA.Warranty.Campaigns@Daimler.com. For other concerns, you may contact the Customer Assistance Center at (800) 385-4357. 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 go to https://www.safercar.gov. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone
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Daimler Trucks North America LLC REF #: ICI20-036 Effective: 11/13/2020 Release: 11/13/2020 SUBJECT: FL863 – Interim Recall Notice This letter is to inform you that an interim recall notice is being sent to affected customers for recall FL863 ~ Freightliner Cascadia Brake Light Illumination. The interim notices will be mailed approximately 11/12/2020. A copy follows for your reference. This notice is for your information only. There is no action for customers or dealers to take. If customers inquire, please refer them to the interim notice. 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 Direct Warranty Customers – U.S. and Canada If you have questions about this Letter, please submit your inquiry on the Web using the WSC Link on DTNAConnect Daimler Trucks North America LLC November 2020 FL863 Interim Recall Notice NHTSA #20V-567 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Freightliner Cascadia Brake Light Illumination This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, has decided that a defect which relates to motor vehicle safety exists on specific Model Year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain pressure switch. On certain vehicles, the brake lights may remain on after release of the brake pedal, which may prevent accurate communication to following vehicles. While the brake lights are on, with additional service brake application, the intensity of brake lights would not change and would not signal to other motorist the intent of the driver to slow the vehicle, potentially leading to an increased risk of a crash. This is the first of two notices you will receive regarding this subject. This letter is to inform you of an upcoming Recall to correct the issue noted above. Daimler Trucks is currently validating the repair. There is no action for you to take at this time. The second notice will inform you when the final remedy is available. When you receive the second notice, please contact your authorized Daimler Trucks North America dealer to schedule the Recall for your vehicle. 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 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 DTNA.Warranty.Campaigns@Daimler.com. For other concerns, you may contact the Customer Assistance Center at (800) 385-4357. 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 go to https://www.safercar.gov. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone
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Models Affected: Specific model year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain brake light pressure switch. General Information Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above. On certain vehicles, the brake lights may remain on after release of the brake pedal, presenting inaccurate information to vehicles which are following, potentially leading to an increased risk of a crash. Vehicles in FL863A are built with Detroit engines and will have the 3-pin switch replaced with a 2-pin switch and a jumper harness. This is the final repair and a sticker must be placed in the door upon completion. Vehicles in INT FL863-01 are built with Cummins engines and will have a 3-pin switch replaced with a new 3-pin switch as an interim repair; DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. Owners in INT FL863-01 will receive a final notice when the final repair for Cummins engines is available. There are approximately 145,444 vehicles involved in this campaign. 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 Final FL863 campaign, check the vehicle for a completion sticker (Form WAR260). Prior to performing the INT FL863 check the OWL Coverage screen for completion. Replacement Parts Replacement parts are now available and can be obtained by ordering the part number(s) listed below from your facing Parts Distribution Center. If our records show your dealership has ordered any vehicle(s) involved in campaign number FL863, a list of the customers and vehicle identification numbers will be available on DTNAConnect. Please refer to this list when ordering parts for this recall. Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 1 Subject: Freightliner Cascadia Brake Light Illumination Campaign Number Part Description Part Number Qty. FL863A (Final) 2-PIN BRAKE LIGHT PRESSURE SWITCH 12-27919-000 JUMPER HARNESS A66-23212-000 1 ea BLANK COMPLETION STICKER WAR260 INT FL863-01 (Interim) 3-PIN BRAKE LIGHT PRESSURE SWITCH 12-26773-000 1 ea Table 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 Corrective Action FL863A Replace brake light pressure switch, install jumper harness (Detroit engines) 0.4 996-R115A 12-Repair Recall/Campaign INT FL863-01 Replace brake light pressure switch (Cummins engines) 0.3 996-R115B 12-Repair Recall/Campaign Table 2 When Final Recall FL863A has been completed, locate the base completion label in the appropriate location on the vehicle, and attach the red completion sticker. (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). Write the recall number on a blank sticker and attach it to the base completion label. IMPORTANT: When Interim Recall INT FL863-01 has been completed, DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. 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: IMPORTANT: When Interim Recall INT FL863-01 has been completed,DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. • Claim type is Recall Campaign. • In the Campaign field, enter the appropriate campaign number. (FL863-A or INT FL863-01). • In the Primary Failed Part Number field, enter 25-FL863-000. • In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table. • In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. Administrative time will be included automatically as SRT 939-6010A for 0.3 hours. Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 2 Table 1 – Replacement Parts for FL863A • The VMRS Component Code is F99-999-005 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. • Include the approved amount on your claim in the Other Charges section. • 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. OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the campaign has not been previously completed. Vehicles in FL863A, check for a completion sticker prior to beginning work. IMPORTANT: No sticker is attached when completing INT FL863-01. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. U.S. and Canadian dealers, contact the Warranty Campaigns Department via Web inquiry at DTNAConnect.com / WSC, 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. Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 3 Copy of Notice to Owners 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 requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, has decided that a defect that relates to motor vehicle safety exists on specific model year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain brake light pressure switch. On certain vehicles, the brake lights may remain on after release of the brake pedal, presenting inaccurate information to vehicles which are following, potentially leading to an increased risk of a crash. For the owners in FL863A: Vehicles in FL863A are built with Detroit engines and will have the 3-pin brake pressure switch replaced with a 2-pin brake pressure switch and jumper harness. This is the FINAL repair. Repairs will be performed by Daimler Trucks North America authorized service facilities. For the owners in INT FL863-01: Vehicles in INT FL863-01 are built with Cummins engines and will have the 3-pin brake pressure switch replaced with a new 3-pin brake pressure switch. This is an INTERIM repair. Repairs will be performed by Daimler Trucks North America authorized service facilities. Owners in INT FL863-01 will receive a final notice when the final repair for Cummins engines is available. 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. On the menu tab, select “Contact,” scroll down to “Find a Dealer,” and select the appropriate brand. The Recall will take approximately one hour and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at this URL: https://dtna-dlrinfo.prd.freightliner.com:48518/VinLookup/vin-module/getVinLookupPage 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. 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 DTNA.Warranty.Campaigns@Daimler.com. For the Notice to U.S. Customers: 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 https://www.safercar.gov. For the Notice to Canadian Customers: If you wish to submit a complaint about this recall, you can contact Transport Canada road safety, 80 rue Noel, Gatineau, Quebec J8Z 0A1 or call (800) 333-0510. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 4 Subject: Freightliner Cascadia Brake Light Illumination WARRANTY CAMPAIGNS DEPARTMENT Enclosure 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. Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 5 Work Instructions Models Affected: Specific model year 2017-2021 Freightliner Cascadia vehicles manufactured March 8, 2016, through January 3, 2020, and equipped with a certain brake light pressure switch. Vehicles in FL863A will have the 3-pin switch replaced with a 2-pin switch and a jumper harness. This is the final repair and a sticker must be placed in the door upon completion. Vehicles in INT FL863-01 will have a 3-pin switch replaced with a new 3-pin switch as an interim repair; DO NOT place a sticker in the door. Please create a draft claim for the campaign as early as possible and file the INT FL863-01 recall claim immediately after completion of work. Pressure Switch Replacement 1. For vehicles in FL863A, check the base label (Form WAR259) for a completion sticker (Form WAR260) indicating this work has been done. The base label is usually located on the passenger side door, about 12inches (30cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. For vehicles in INT FL863-01, please check the OWL coverage screen indicating this work has been completed. 2. Park the vehicle, apply the parking brakes, and shut down the engine. Chock the tires. 3. Remove the lower steering column and throttle cover dash panels. If instructions are needed, see the New Cascadia Workshop Manual Section 60.06.100 Dash Panels Removal and Installation. NOTE: Depending on the vehicle build date, the 3-pin brake light pressure switch may be in one of two locations on the pass-through switch manifold. See Fig. 1. 4. Disconnect and remove the 3-pin brake light pressure switch. 10/22/2021 f547678 1 2 1. Initial 3-Pin Brake Pressure Switch Location 2. Alternate 3-Pin Brake Pressure Switch Location Fig. 1, Possible 3-Pin Brake Light Pressure Switch Locations Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 6 Subject: Freightliner Cascadia Brake Light Illumination 5. Install the new pressure switch. Vehicles in FL863A, continue to next step. Vehicles in INT FL863-01, go to step 5.3. 5.1 Install the 2-pin pressure switch on vehicles in FL863A. Torque the switch 7 to 9 lbf·ft (9.5 to 12 N.m) See Fig. 2. 12/14/2018 f546910 Fig. 2, Tightening the Brake Light Pressure Switch Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 7 5.3 Install the new 3-pin pressure switch on vehicles in INT FL863-01. Torque the switch 7 to 9 lbf·ft (9.5 to 12 N·m). See Fig. 2. Then reconnect the existing connector. 6. Install the lower steering column and throttle cover dash panels. If instructions are needed, see the New Cascadia Workshop Manual Section 60.06.100 Dash Panels Removal and Installation. 7. Vehicles in INT FL863-01, DO NOT place a sticker in the door. File the INT FL863-01 recall claim immediately after completion of work. Vehicles in FL863A, clean a spot on the base label (Form WAR259). Write the recall number, FL863-A, on a blank red completion sticker (Form WAR260), and attach it to the base label to indicate this recall has been completed. 12/09/2020 f547427 Fig. 3, Jumper Harness 12/09/2020 f547429 Fig. 4, Jumper Harness Connected to Cab Harness Daimler Trucks North America LLC Recall Campaign November 2021 FL863A (Final) INT FL863-01 (Interim) NHTSA #20V-567 Transport Canada #2020-444 Page 8 5.2 Install the jumper harness (see Fig. 3) onto the dash connector (see Fig. 4) and then connect it to the new 2-pin brake light pressure switch. Continue to step 6.
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