March 24, 2021 NHTSA CAMPAIGN NUMBER: 21V206000

Undersized Ground Wire May Cause Engine Stall

Damage to the ground harness may cause an engine stall, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V206

Manufacturer Daimler Trucks North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 5,111

 

Summary

Daimler Trucks North America, LLC (DTNA) is recalling certain 2019-2021 Western Star 4700 and Western Star 5700 vehicles. The ground harness wiring may be undersized and may cause a connector to melt.

 

Remedy

DTNA will notify owners, and dealers will replace the ground harness, free of charge. The recall is expected to begin May 22, 2021. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-880.

 

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

 

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Daimler Trucks
North America LLC

 

May 2021
FL880
Interim Recall Notice
NHTSA #21V-206

 

IMPORTANT SAFETY RECALL

See enclosed VIN list

Subject: Western Star ACM Ground Splice Pack

 

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 wholly owned subsidiary, Western Star Truck Sales, Inc., has decided that a defect, which relates to motor vehicle safety, exists on specific Model Year 2019-2022 Western Star 4700 and 5700 model vehicles manufactured October 24, 2018, through March 15, 2021.

 

On certain vehicles, the ground harness wiring might be undersized, which may result in a melted ground splice connector in the ground circuit harness. If the connector does become damaged, under certain circumstances, the engine may stall without the ability to restart, increasing the 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 securing replacement parts. 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 [email protected]. 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

 

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Daimler Trucks
North America LLC

Recall Campaign

July 2021
FL880A-E
NHTSA #21V-206
Transport Canada #2021-172

 

Subject: Western Star ACM Ground Splice Pack

Models Affected: Specific model year 2019-2022 Western Star 4700 and 5700 vehicles manufactured October 24, 2018, through March 15, 2021.

 

General Information

Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Western Star Truck Sales, Inc., has decided that a defect which relates to motor vehicle safety exists on the vehicles mentioned above.

On certain vehicles, the ground harness wiring might be undersized, which may result in a melted ground splice connector in the ground circuit harness. If the connector does become damaged, under certain circumstances, the engine may stall without the ability to restart, increasing the risk of a crash.

The ground harness will be replaced. Repairs will be performed by Daimler Trucks North America authorized service facilities.

There are approximately 6,500 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 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 and/or 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 FL880, 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.

 

Table 1 – Replacement Parts for FL880

Campaign Number	Part Description	Part Number	Qty.
FL880A,C	HARN-GND_PWRTN,ENG,OL,1US	A66-13193-012	1 ea
FL880B	HARN-GND_PWRTN,ENG,OL,DT,HDEP	A66-13193-011	1 ea
	HARN-GND_PWRTN,ENG,OL,1US	A66-13193-012	1 ea
FL880D,E	HARN-GND_PWRTN,ENG,OL,1MC,2V2	A66-13193-013	1 ea
FL880A-E	BLANK COMPLETION STICKER	WAR260	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
FL880A,C,D,E	HARNESS, GROUND, ATD ONLY	2.5	996-R122B	12-Repair Recall/Campaign
FL880B	HARNESSES, GROUND, BOTH DT12 & ATD	3.3	996-R122A	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.

 

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 condition code (e.g. FL880-A, FL880B, etc.).
• In the Primary Failed Part Number field, enter 25-FL880-000.
• In the Parts field, enter the appropriate kit or 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 for all vehicles.
• 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.

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.

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.

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Copy of Notice to Owners

Subject: Western Star ACM Ground Splice Pack

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 wholly owned subsidiary, Western Star Truck Sales, Inc., has decided that a defect, which relates to motor vehicle safety, exists on specific Model Year 2019-2022 Western Star 4700 and 5700 model vehicles manufactured October 24, 2018, through March 15, 2021.

On certain vehicles, the ground harness wiring might be undersized, which may result in a melted ground splice connector in the ground circuit harness. If the connector does become damaged, under certain circumstances, the engine may stall without the ability to restart, increasing the risk of a crash.

The ground harness will be replaced. 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 the Recall performed and to ensure that parts are available at the dealership. To locate an authorized dealer, go to

Daimler-TrucksNorthAmerica.com/contact-us/. Scroll down to “Locate a Dealer,” and select the appropriate brand. The Recall will take approximately three hours 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

[email protected]. 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.

WARRANTY CAMPAIGNS DEPARTMENT

Enclosure

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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.

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Work Instructions

Subject: Western Star ACM Ground Splice Pack

Models Affected: Specific model year 2019-2022 Western Star 4700 and 5700 vehicles manufactured October 24, 2018, through March 15, 2021.

See Table 3 for campaign number, scope of work, and work instruction page number.

Campaign Number	Scope of Work	Page Number
FL880A, C	Step Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation	11
FL880B	DT12 Transmission Ground Circuit Overlay Harness Installation	6
	Step Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation	11
FL880D, E	Mid or Vertical Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation	16

 

Table 3

 

FL880B – DT12 Transmission Ground Circuit Overlay Harness Installation

1. Check the base label (Form WAR259) for a completion sticker for FL880 (Form WAR 260) indicating this work has been done. The base label is usually located on the passenger-side door about 12 inches (30cm) below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is not present, continue with the next step.
2. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
3. Disconnect negative battery cables at the batteries.
4. Locate the transmission control unit (TCU) 21-pin connector TRANS_CTRL_D_ECU_TCU_DD_1A, and disconnect it. See Fig. 1.

 

Fig. 1, TCU 21-Pin Connector TRANS_CTRL_D_ECU_TCU_DD_1A Location

 

5. Remove the 21-pin connector back shell cover, tie straps and harness wrap to access the terminals and wiring.
6. Using tool DKIOCHA17002-1, or similar, release the yellow secondary lock by moving it away from the terminals until a slight click is heard or felt. See Fig. 2 and Fig. 3.

 

Fig. 2, TRANS_CTRL_D_ECU_TCU_DD_1A Connector

 

Fig. 3, Releasing the 21-Pin Connector Secondary Lock

 

7. Using tool DKOCHA17002-8, extract the four GNDE wires from the TCU connector cavities 16, 19, 20, and 21. See Fig. 4 and Fig. 5.

 

Fig. 4, TRANS_CTRL_D_ECU_TCU_DD_1A Connector Pin Configuration

 

Fig. 5, TRANS_CTRL_D_ECU_TCU_DD_1A Connector Wiring

 

8. Blunt cut the GNDE wires extracted from the TCU 21-pin connector TRANS_CTRL_D_ECU_TCU_DD_1A near the terminals. Apply shrink tube to the blunt cut wires, and secure them to the harness. See Fig. 6 and Fig. 7.

 

Fig. 6, Blunt Cut Wire at TCU 21-Pin Connector

 

Fig. 7, Shrink Tube Applied to the Blunt Cut Wires

 

9. Remove the left-hand (LH) side cab mounted skirts for a better access to route the overlay harness. See Fig. 8.

 

Fig. 8, Cab Mounted Skirt Removal

 

NOTE: The DT12 TCU ground overlay harness A66-13193-011 has an additional circuit which is not required.

This circuit is typically routed to the PTPDM, and back to the LH side splice, and will not be used for this repair. A circuit is already incorporated into the existing wiring on the vehicle, to meet its purpose.

10. Remove the circuit from the A66-13193-011 harness as shown in Fig. 9. Once removed, the harness will now have four terminals at the TCU side, and a striped wire at the other end.

 

A. Remove this circuit from the A66-13193-011 harness.
1. GND_PWRTN_ENG_O_S_GNDE_5A (four wires should be present at this end of harness A66-13193-011)
2. GND_PWRTN_ENG_O_S_GNDE_2A (one striped wire should be present at this end of harness A66-13193-011)

Fig. 9, Removing the Additional Circuit from A66-13193-011 Harness

 

11. Wrap the new ground overlay harness A66-13193-011 with protective fiber wrap, to protect the wires from chafing.
12. Install DT12 TCU ground overlay harness A66-13193-011 by inserting the four GNDE wires into the TCU21-pin connector cavities 16, 19, 20, and 21. See Fig. 4.
13. Install the TCU 21-pin connector back shell cover and the yellow secondary lock.
14. Secure, wrap, and seal the 21-pin connector to the overlay harnesses with electrical tape.
15. Connect the 21-pin connector to the TCU.
16. Route and secure the new overlay harness A66-13193-011 along the existing harness to the cab frontwall, to be spliced into the GNDE 6ga wire near the single wire bullet connector. See Fig. 10.

 

Fig. 10, Overlay Harness A66-13193-011 Splice Location

 

IMPORTANT: If the new overlay harness A66-13193-011 is not long enough, splice an additional wire of the same size and type, using a Sta-Dry® butt connector. Wrap the splice and additional wiring with protective fiber wrap.

The ground bullet connector wire, which is routed to the Mega Ground Junction Block (MGJB), must remain intact.

17. Disconnect the ground bullet connector GND_PWRTN_ENG_O_FW_GNDE_1A located on the frontwall, near the bulkhead connector. See Fig. 10.
18. As needed, remove the tie straps and the harness wrap to access the 6ga wire on the engine harness A6613193-000 side. Cut the 6ga wire approximately six inches from the bullet connector. See Fig. 10.

IMPORTANT: Crimping, soldering, shrink tube application and fiber wrapping at 6ga wire splice should be performed only after the ATD overlay harness is routed to the splice area.

19. Strip the ends of the 6ga wire from the bullet connector, and the ends of the 12ga wire from the new overlay harness A66-13193-011. Install a barrel splice PHM 8 4920, and a dual wall shrink tube A23-13823-000 to seal the wiring after crimping and soldering. See Fig. 11.

 

Fig. 11, Overlay Harness A66-13193-011 Spliced

 

20. Go to heading Step Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation

 

FL880A, B, C – Step Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation

1. Check the base label (Form WAR259) for a completion sticker for FL880 (Form WAR 260) indicating this work has been done. The base label is usually located on the passenger-side door about 12 inches (30cm) below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is not present, continue with the next step.
2. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
3. Disconnect negative battery cables at the batteries.
4. Locate the ATD 18-pin connector ENG_CTRL_ENG_O_ACM_ON_ATD_1A near the frame rail under the rear-right side of the cab, and disconnect it. See Fig. 12.

 

Fig. 12, ATD 21-Pin Connector ENG_CTRL_ENG_O_ACM_ON_ATD_1A Location

 

5. Using tool DKIOCHA17002-1, or similar, release the green secondary lock. See Fig. 13.

 

Fig. 13, ATD 18-Pin Connector Green Secondary Lock

 

6. Using tool DKOCHA17002-8, extract the five GNDE wires from the TCU connector cavities 13, 14, 15, 16, and 17. See Fig. 14. and Fig. 15.

 

Fig. 14, ATD 18-Pin Connector Pin Configuration

 

Fig. 15, ATD 18-Pin Connector Wiring

 

7. Blunt cut the GNDE wires extracted from the ATD 18-pin connector ENG_CTRL_ENG_O_ACM_ON_ATD_1A near the terminals. Apply shrink tube to the blunt cut wires, and secure them to the harness.

8. If not already removed, remove the LH and RH side cab mounted skirts for a better access to route the overlay harness. See Fig. 8.
9. Wrap the new ground overlay harness A66-13193-012 with protective fiber wrap, to protect the wires from chafing.
10. Install the step mounted ATD ground overlay harness A66-13193-012 by inserting the five GNDE wires into the ATD 18-pin connector cavities 13, 14, 15, 16, and 17. See Fig. 14.
11. Install the ATD 18-pin connector green secondary lock. See Fig. 13.
12. Connect the 18-pin ATD connector.
13. Starting from the ATD 18-pin connector side, apply the heat protection wrap A66-03960-007 to harness A6613193-012 for about 12 inches (305 mm). See Fig. 16.

 

Fig. 16, Heat Protection Wrap A66-03960-007

 

14. Route and secure the new overlay harness A66-13193-012 along with the existing harness to the cab frontwall, to be spliced into the GNDE 6ga wire near the single wire bullet connector. See Fig. 10.

IMPORTANT: If the new overlay harness A66-13193-012 is not long enough, splice an additional wire of the same size and type, using a Sta-Dry® butt connector. Wrap the splice and additional wiring with protective fiber wrap.

The ground Bullet connector wire, which is routed to the MGJB must remain intact.

15. Disconnect the ground bullet connector GND_PWRTN_ENG_O_FW_GNDE_1A located on the frontwall, near the bulkhead connector. See Fig. 10.
16. As needed, remove the tie straps and harness wrap to access the 6ga wire on the engine harness A66-13193-000 side. Cut the 6ga wire approximately eight inches from the bullet connector. See Fig. 10.

IMPORTANT: For campaign group FL880B; crimping, soldering, shrink tube application and fiber wrapping at 6ga wire splice should be performed only after the DT12 transmission overlay harness is routed to the splice area.

17. Strip the ends of the 6ga wire from the bullet connector, and the ends of the 12ga wire from the new overlay harness A66-13193-012. Install a barrel splice PHM 8 4920, and a dual wall shrink tube A23-13823-000 to seal the wiring after crimping and soldering. See Fig. 11.
18. Once all the wires are routed to the splice, crimp, solder, apply shrink tube, and then wrap the harness tocomplete the splice. See Fig. 17.

 

Fig. 17, Heat Shrink Applied to the Splice

 

19. Connect the bullet connector.
20. Wrap the exposed part of the installed overlay harness/harnesses with appropriate harness wrap and electrical tape. Route and secure the new overlay harness/harnesses along the applicable existing harness/ harnesses using tie straps and electrical tape. See Fig. 18.

 

Fig. 18, Completed Repair

 

21. Ensure all the connectors, blunt cut wires, and overlay harness connectors are secured.
22. If removed, install the LH and RH side cab mounted skirts.
23. Connect the battery negative cable at the batteries.
24. Start and run the vehicle for one minute to verify the repair.
25. Clean a spot on the base label (Form WAR259). Write the recall number, FL880, on a blank red completion sticker (Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

FL880D, E – Mid or Vertical Mounted Aftertreatment Device (ATD) Ground Overlay Harness Installation

1. Check the base label (Form WAR259) for a completion sticker for FL880 (Form WAR 260) indicating this work has been done. The base label is usually located on the passenger-side door about 12 inches (30cm) below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is not present, continue with the next step.
2. Park the vehicle on a level surface, shut down the engine, and apply the parking brakes. Chock the tires.
3. Disconnect negative battery cables at the batteries.
4. Locate the ATD 14-pin connector ATD_ENG_O_JMPR_ACM_4A within the after-treatment harness on or near the transmission. See Fig. 19.

 

Fig. 19, ATD 14-Pin Connector ATD_ENG_O_JMPR_ACM_4A Location

 

5. To disconnect the ATD 14-pin connector, unlock it by sliding the red lock tab. Press the lock tab and gently pull the connector out. See Fig. 19.
6. Using needle nose pliers, grab the blue secondary lock by the tab in the center, and pull it out from the connector.
7. Using tool DKOCHA17002-8, extract the two GNDE wires from the TCU connector cavities 2 and 11. See Fig. 20.
8. Blunt cut the GNDE wires extracted from the ATD 14-pin connector ATD_ENG_O_JMPR_ACM_4A near the terminals. Apply shrink tube to the blunt cut wires, and secure them to the harness.
9. If not already removed, remove the LH and RH side cab mounted skirts for a better access to route the overlay harness. See Fig. 8.
10. Wrap the new ground overlay harness A66-13193-013 with protective fiber wrap, to protect the wires from chafing.
11. Install the mid/vertical mounted ATD ground overlay harness A66-13193-013 by inserting the two GNDE wires into the ATD 14-pin connector cavities 2 and 11. See Fig. 20.
12. Install the ATD 14-pin connector blue secondary lock.
13. Connect the 14-pin ATD connector.
14. Route and secure the new overlay harness A66-13193-013 along the existing harness to the cab frontwall, to be spliced into the GNDE 6ga wire near the single wire bullet connector. See Fig. 10.

IMPORTANT: If the new overlay harness A66-13193-013 is not long enough, splice an additional wire of the same size and type, using a Sta-Dry® butt connector. Wrap the splice and additional wiring with protective fiber wrap.

The ground Bullet connector wire, which is routed to the MGJB, must remain intact.

15. Disconnect the ground bullet connector GND_PWRTN_ENG_O_FW_GNDE_1A located on the frontwall, near the bulkhead connector. See Fig. 10.
16. As needed, remove the tie straps and harness wrap to access the 6ga wire on the engine harness A66-13193-000 side. Cut the 6ga wire approximately eight inches from the bullet connector. See Fig. 10.
17. Strip the ends of the 6ga wire from the bullet connector, and the ends of the 12ga wire from the new overlay harness A66-13193-013. Install a barrel splice PHM 8 4920, and a dual wall shrink tube A23-13823-000 to seal the wiring after crimping and soldering. See Fig. 11.
18. Crimp, solder, apply shrink tube, and then wrap the harness to complete the splice. See Fig. 17.
19. Connect the bullet connector.
20. Wrap exposed part of the installed overlay harness with appropriate harness wrap and electrical tape. Route and secure the new overlay harness along the applicable existing harness using tie straps and electrical tape. See Fig. 18.
21. Ensure all the connectors, blunt cut wires, and overlay harness connectors are secured.
22. If removed, install the LH and RH side cab mounted skirts.
23. Connect the battery negative cable at the batteries.
24. Start and run the vehicle for one minute to verify the repair.
25. Clean a spot on the base label (Form WAR259). Write the recall number, FL880, on a blank red completion sticker (Form WAR260), and attach it to the base label to indicate this recall has been completed.

 

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6 Affected Products

Vehicles

MAKE	MODEL	YEAR
WESTERN STAR	4700	2019-2021
WESTERN STAR	5700	2019-2021

 

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10 Associated Documents

Recall Acknowledgement

RCAK-21V206-6036.pdf 645.764KB

 

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Miscellaneous Document- Defect Information Report

RMISC-21V206-1838.pdf 758.061KB

 

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Defect Notice 573 Report

RCLRPT-21V206-1599.PDF 214.111KB

 

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Miscellaneous Document- Defect Information Report

RMISC-21V206-5446.pdf 759.03KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V206-7174.pdf 256.019KB

 

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V206-6455.pdf 138.367KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V206-3245.pdf 143.54KB

 

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Recall Quarterly Report #1, 2021-3

RCLQRT-21V206-0218.PDF 211.156KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V206-9392.pdf 1522.253KB

 

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Recall Quarterly Report #2, 2021-4

RCLQRT-21V206-9595.PDF 211.26KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V206&docType=RCL

 

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