FL887 – Dislodged Headlight May Cause Fire – 2017-2022 Freightliner Cascadia

SEOCONTENT-START Defect Information Report (Section 573.6) FL-887 Date of Submission: May 14, 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: 2022 Make: Freightliner Model: New Cascadia Production Dates: Begin: 03/08/2016 End: 05/10/2021 Descriptive Information: On the affected Freightliner Cascadia trucks within the production dates noted above Number potentially involved: 72508 Estimated percentage involved with defect: 1.0% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain Freightliner Cascadia vehicles, if halogen headlight/headlamp bulb is improperly installed upon replacement, that headlight/headlamp bulb may potentially dislodge and come into contact with other components of the headlight/headlamp assembly, increasing the risk of a melting condition or fire. Although DTNA does not believe this to be a defect related to motor vehicle safety within the meaning of the National Traffic and Motor Vehicle Safety Act, out of an abundance of caution DTNA is recalling vehicles with these halogen headlight/headlamp bulbs. If a noncompliance, provide the applicable FMVSS Describe the safety risk: If a replacement bulb is improperly installed, it may melt beyond the headlight/headlamp assembly to potentially include the hood, cab and complete vehicle, increasing the risk of fire. 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 mid-June 2018, DTNA received one field report of a melted headlamp socket with a replacement headlamp (not resulting in a fire or other thermal event), prompting DTNA to open a preliminary investigation. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 8/20/2018. In or about late June through July 2018, DTNA examined the matter and, among other things, sought to identify potentially similar incidents. During that time frame, none were found. In or about August 2018, DTNA received a second field report involving a replacement headlamp that had overheated and melted approximately 11 months after replacement. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 11/30/2018. As of August 2018, DTNA’s reasonable understanding of the facts presented in these first two field reports supported an owner aftermarket installation error for replacement headlamps and not a safety-related defect. In or about October of 2018, DTNA determined that the headlamp supplier was preforming air pressure testing to confirm proper bulb placement into the assembly. DTNA also reviewed the relevant Service/Workshop Manual information for Halogen headlight repair/service resulting in an update request to align halogen bulb replacement with other models. Additionally, in or about early October 2018, DTNA received a third field report of a thermal event for a truck that had the headlight serviced twice prior. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 3/1/2019. DTNA’s reasonable understanding of the facts presented in that field report continued to illustrate an owner aftermarket installation error for replacement headlamps and not a safety-related defect. Towards the later part of October 2018, a cross-function team was tasked to conduct a headlamp accessibility test evaluation. Subsequently, in or about December 2018, DTNA compared customer supplied aftermarket replacement bulb to OEM bulb (the results of which are discussed below). Also, a fourth headlamp melt field report was received followed by a DTNA comparison review of customer supplied aftermarket vs OEM bulbs. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 3/1/2019. DTNA’s reasonable understanding of the facts presented in that field report again continued to illustrate an owner aftermarket installation error for replacement headlamps, and not a safety-related defect. In or about January 2019, the headlamp supplier conducted an accessibility review and DTNA reviewed the aforementioned PVE testing results, following which DTNA updated applicable installation diagrams noting the importance of proper owner installation, bulb orientation, quality alert at DTNA plants for awareness, and a service bulletin/driver manual update. In or about late January 2019, DTNA closed its investigation, reasonably concluding no defect that presented an unreasonable risk to safety, with all issues arising from improper after first sale owner installation of replacement bulbs. In or about February 2019, DTNA updated its Workshop Manual, and an initial Service Bulletin (54-309) was published to use SAE/DOT approved bulbs only. Among other things, it cautioned installers to ensure proper installation with bulb firmly seated in headlamp housing and that improper bulb installation may result in melting or fire damage to vehicle. This Service Bulletin was timely submitted to NHTSA pursuant to 49 C.F.R. 579.5 in or about 3/7/2019. Over the course of January to July 2019, DTNA conducted design reviews considering accessibility improvements and warning labels in connection with owner error in bulb replacement. During this time period, 8 additional headlamp failure reports were received from the field. These field reports were also all timely submitted to NHTSA pursuant to 49 C.F.R. 579.22. In or about August 2019, a warning label was developed. Viewing window opening in splash shield was reviewed in September 2019. In or about October 2019, DTNA issued a service option for warning labels, splash shield modification, and removal of bulb boot for installation of a foam donut. Later, in or about November 2019, DTNA issued a Customer Advisory Letter (CAL) regarding splash shield modification (2” visibility hole), warning label and grommet. This CAL was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 11/21/2019. In or about December 2019, Service Bulletin (54-309) revision was published with warning label addition. This Service Bulletin was timely submitted to NHTSA pursuant to 49 C.F.R. 579.5 in or about 12/19/2019. In or about June 2020, additional DTNA workshop manual and drivers manual updates were published, all of which were timely submitted to NHTSA pursuant to 49 C.F.R. 579.5. During a December 2020 meeting with NHTSA, the agency inquired as to DTNA’s analysis of replacement headlight failures. In response to NHTSA’s inquiry, in January 2021, DTNA conducted a warranty data pull, and determined the population finalizing the warranty review by mid-January. DTNA’s preliminary findings were discussed with NHTSA in or about mid-January 2021. Given NHTSA’s inquiry, in January and February 2021, DTNA re-examined the matter and identified additional field incidents arising between August 2019 and November 2020, including approximately 24 incidents involving P4 Cascadias with comparable thermal incidents that resulted in melting of components and in some cases total vehicle loss. On February 25, 2021, NHTSA opened PE21-006 to investigate halogen headlamp issues. DTNA reevaluated the matter, including efforts to assess relevant failure mechanisms. In late April and early May, 2021 DTNA reevaluated the data on vehicles found to have thermal events at low mileage and decided to take a more conservative approach. While the issue is and was best understood as an owner aftermarket installation error for replacement headlamps, out of an abundance of caution, and without finding a safety-related defect, DTNA decided on May 10, 2021 to conduct a voluntary recall on the affected population of Freightliner New Cascadias. At all relevant times prior to May 10, 2021, given the facts as they were best understood at the time, DTNA reasonably did not know, nor could it have known, of a potential defect with an unreasonable risk to safety. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. Subject vehicles will require, on both sides of the vehicle, a foam grommet to replace the rubber boot within the headlight/headlamp assembly, a 4 inch access hole cut into the inner fender, and a warning label/sticker on both fenders. 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: 07/12/2021 Planned Dealer Notification End Date: 07/12/2021 Planned Owner Notification Begin Date: 07/12/2021 Planned Owner Notification End Date: 07/12/2021 Manufacture’s identification code for this recall (if applicable): FL-887 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs *********************************************************************************************************************** Defect Information Report (Section 573.6) FL-887 Date of Submission: June 16, 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: 2022 Make: Freightliner Model: New Cascadia Production Dates: Begin: 03/08/2016 End: 05/20/2021 Descriptive Information: On the affected Freightliner Cascadia trucks within the production dates noted above Number potentially involved: 72510 Estimated percentage involved with defect: 1.0% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain Freightliner Cascadia vehicles, if halogen headlight/headlamp bulb is improperly installed upon replacement, that headlight/headlamp bulb may potentially dislodge and come into contact with other components of the headlight/headlamp assembly, increasing the risk of a melting condition or fire. Although DTNA does not believe this to be a defect related to motor vehicle safety within the meaning of the National Traffic and Motor Vehicle Safety Act, out of an abundance of caution DTNA is recalling vehicles with these halogen headlight/headlamp bulbs. If a noncompliance, provide the applicable FMVSS: N/A Describe the safety risk: If a replacement bulb is improperly installed, it may melt beyond the headlight/headlamp assembly to potentially include the hood, cab and complete vehicle, increasing the risk of fire. 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 mid-June 2018, DTNA received one field report of a melted headlamp socket with a replacement headlamp (not resulting in a fire or other thermal event), prompting DTNA to open a preliminary investigation. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 8/20/2018. In or about late June through July 2018, DTNA examined the matter and, among other things, sought to identify potentially similar incidents. During that time frame, none were found. In or about August 2018, DTNA received a second field report involving a replacement headlamp that had overheated and melted approximately 11 months after replacement. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 11/30/2018. As of August 2018, DTNA’s reasonable understanding of the facts presented in these first two field reports supported an owner aftermarket installation error for replacement headlamps and not a safety-related defect. In or about October of 2018, DTNA determined that the headlamp supplier was preforming air pressure testing to confirm proper bulb placement into the assembly. DTNA also reviewed the relevant Service/Workshop Manual information for Halogen headlight repair/service resulting in an update request to align halogen bulb replacement with other models. Additionally, in or about early October 2018, DTNA received a third field report of a thermal event for a truck that had the headlight serviced twice prior. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 3/1/2019. DTNA’s reasonable understanding of the facts presented in that field report continued to illustrate an owner aftermarket installation error for replacement headlamps and not a safety-related defect. Towards the later part of October 2018, a cross-function team was tasked to conduct a headlamp accessibility test evaluation. Subsequently, in or about December 2018, DTNA compared customer supplied aftermarket replacement bulb to OEM bulb (the results of which are discussed below). Also, a fourth headlamp melt field report was received followed by a DTNA comparison review of customer supplied aftermarket vs OEM bulbs. This field report was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 3/1/2019. DTNA’s reasonable understanding of the facts presented in that field report again continued to illustrate an owner aftermarket installation error for replacement headlamps, and not a safety-related defect. In or about January 2019, the headlamp supplier conducted an accessibility review and DTNA reviewed the aforementioned PVE testing results, following which DTNA updated applicable installation diagrams noting the importance of proper owner installation, bulb orientation, quality alert at DTNA plants for awareness, and a service bulletin/driver manual update. In or about late January 2019, DTNA closed its investigation, reasonably concluding no defect that presented an unreasonable risk to safety, with all issues arising from improper after first sale owner installation of replacement bulbs. In or about February 2019, DTNA updated its Workshop Manual, and an initial Service Bulletin (54-309) was published to use SAE/DOT approved bulbs only. Among other things, it cautioned installers to ensure proper installation with bulb firmly seated in headlamp housing and that improper bulb installation may result in melting or fire damage to vehicle. This Service Bulletin was timely submitted to NHTSA pursuant to 49 C.F.R. 579.5 in or about 3/7/2019. Over the course of January to July 2019, DTNA conducted design reviews considering accessibility improvements and warning labels in connection with owner error in bulb replacement. During this time period, 8 additional headlamp failure reports were received from the field. These field reports were also all timely submitted to NHTSA pursuant to 49 C.F.R. 579.22. In or about August 2019, a warning label was developed. Viewing window opening in splash shield was reviewed in September 2019. In or about October 2019, DTNA issued a service option for warning labels, splash shield modification, and removal of bulb boot for installation of a foam donut. Later, in or about November 2019, DTNA issued a Customer Advisory Letter (CAL) regarding splash shield modification (2” visibility hole), warning label and grommet. This CAL was timely submitted to NHTSA pursuant to 49 C.F.R. 579.22 in or about 11/21/2019. In or about December 2019, Service Bulletin (54-309) revision was published with warning label addition. This Service Bulletin was timely submitted to NHTSA pursuant to 49 C.F.R. 579.5 in or about 12/19/2019. In or about June 2020, additional DTNA workshop manual and drivers manual updates were published, all of which were timely submitted to NHTSA pursuant to 49 C.F.R. 579.5. During a December 2020 meeting with NHTSA, the agency inquired as to DTNA’s analysis of replacement headlight failures. In response to NHTSA’s inquiry, in January 2021, DTNA conducted a warranty data pull, and determined the population finalizing the warranty review by mid-January. DTNA’s preliminary findings were discussed with NHTSA in or about mid-January 2021. Given NHTSA’s inquiry, in January and February 2021, DTNA re-examined the matter and identified additional field incidents arising between August 2019 and November 2020, including approximately 24 incidents involving P4 Cascadias with comparable thermal incidents that resulted in melting of components and in some cases total vehicle loss. On February 25, 2021, NHTSA opened PE21-006 to investigate halogen headlamp issues. DTNA reevaluated the matter, including efforts to assess relevant failure mechanisms. In late April and early May, 2021 DTNA reevaluated the data on vehicles found to have thermal events at low mileage and decided to take a more conservative approach. While the issue is and was best understood as an owner aftermarket installation error for replacement headlamps, out of an abundance of caution, and without finding a safety-related defect, DTNA decided on May 10, 2021 to conduct a voluntary recall on the affected population of Freightliner New Cascadias. At all relevant times prior to May 10, 2021, given the facts as they were best understood at the time, DTNA reasonably did not know, nor could it have known, of a potential defect with an unreasonable risk to safety. Two vehicles, now being added to the population, were inadvertently not included in the original recall population due to 2021 supply chain issues and parts shortages that shifted their build dates and delivery dates to two customers until after DTNA’s original recall filing with NHTSA. DTNA promptly discovered the existence of these two additional vehicles and contacted the two customers at approximately the time the vehicles were delivered to those customers. DTNA ensured the customers understood the recall issue for the two additional vehicles and now adds these two additional vehicles to the recall population. *June 2021: DTNA is in the process of sunsetting the terminology “New Cascadia” and transitioning to just “Cascadia.” Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. Subject vehicles will require, on both sides of the vehicle, a foam grommet to replace the rubber boot within the headlight/headlamp assembly, a 4 inch access hole cut into the inner fender, and a warning label/sticker on both fenders. 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: 07/12/2021 Planned Dealer Notification End Date: 07/12/2021 Planned Owner Notification Begin Date: 07/12/2021 Planned Owner Notification End Date: 07/12/2021 Manufacture’s identification code for this recall (if applicable): FL-887 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs *********************************************************************************************************************** Daimler Internal Daimler Trucks North America LLC July 2021 FL887A NHTSA #21V-357 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Cascadia Halogen Headlights 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 that relates to motor vehicle safety exists on specific Model Year 2017-2022 Freightliner Cascadia vehicles manufactured March 8, 2016, through May 10, 2021, and equipped with halogen headlights. On certain vehicles, if halogen headlight bulb is improperly installed upon replacement, that headlight bulb may potentially dislodge and come into contact with other components. If a replacement bulb is improperly installed, it may melt beyond the headlight assembly to potentially include the hood, cab and complete vehicle, increasing the risk of fire. Vehicles will be inspected for a 4-inch access hole, foam grommets, and warning labels; and will be repaired as needed. 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, search online at Daimler-TrucksNorthAmerica.com/Contact-us. Scroll down to “Locate 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 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 Daimler Internal Daimler Trucks North America LLC 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 Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone *********************************************************************************************************************** Subject: Cascadia Halogen Headlights Models Affected: Specific model year 2017-2022 Freightliner Cascadia vehicles manufactured March 8, 2016, through May 10, 2021, and equipped with halogen headlights. 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. There are approximately 73,780 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 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 FL887, 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 FL887 Campaign Number Part Description Part Number Qty. FL887A FOAM GROMMET 66-19944-000 4 ea WARNING LABEL 24-02029-000 2 ea 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. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 1 On certain vehicles, if halogen headlight bulb is improperly installed upon replacement, that headlight bulb may potentially dislodge and come into contact with other components. If a replacement bulb is improperly installed, it may melt beyond the headlight assembly to potentially include the hood, cab and complete vehicle, increasing the risk of fire. Vehicles will be inspected for a 4-inch access hole, foam grommets, and warning labels; and will be repaired as needed. Labor Allowance Table 2 – Labor Allowance Campaign Number Procedure Time Allowed (hours) SRT Code Corrective Action FL887A Inspect and repair halogen headlights 0.7 996-R121A 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 (FL887-A). • In the Primary Failed Part Number field, enter 25-FL887-000. • 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. • 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. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 2 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 July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 3 Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Copy of Notice to Owners Subject: Cascadia Halogen Headlights 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 2017-2022 Freightliner Cascadia vehicles manufactured March 8, 2016, through May 10, 2021, and equipped with halogen headlights. 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 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 go 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 Page 4 On certain vehicles, if halogen headlight bulb is improperly installed upon replacement, that headlight bulb may potentially dislodge and come into contact with other components. If a replacement bulb is improperly installed, it may melt beyond the headlight assembly to potentially include the hood, cab and complete vehicle, increasing the risk of fire. Vehicles will be inspected for a 4-inch access hole, foam grommets, and warning labels; and will be repaired as needed. 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 July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 5 Work Instructions Subject: Cascadia Halogen Headlights Models Affected: Specific model year 2017-2022 Freightliner Cascadia vehicles manufactured March 8, 2016, through May 10, 2021, and equipped with halogen headlights. Halogen Headlight Repair 1. Check the base label (Form WAR259) for a completion sticker for FL887 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger-side door about 12 inches (30 cm) 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, shut down the engine, and apply the parking brakes. Chock the tires. 3. Open the hood. NOTICE Drilling holes in the splash shield without removing them from the vehicle may damage the hood and headlight wiring. Marking and drilling holes in the splash shield is safer, accurate and easier if done on a workbench. IMPORTANT: For a more controlled and clean cut using a hole saw, drill the holes with the drill tool set to rotate counterclockwise. This will also reduce the amount of deburring required after drilling. 4. Remove the hood mounted splash shields at both sides. For instructions, refer to Group 88 of the New Cascadia ™ Workshop Manual. 5. Inspect the splash shields for existing inspection holes. See Fig. 1. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 6 11/04/2019 f547040 A A 1 2 3 4 A. Measure 7 inches from the tip of the splash shield along the centerline to mark where the center of the sight hole should be. 1. Left-Hand Side Hood-Mounted Splash Shield 2. Right-Hand Side Hood-Mounted Splash Shield 3. Centerline 4. Sight Hole Location Fig. 1, Hood-Mounted Splash Shield Hole Locations • If no holes exist, go to the next step. • If 2-inch diameter holes exist, go to step 7. • If 4-inch diameter holes exist, go to step 8. 6. Drill a 4-inch hole in both the hood mounted splash shields as follows. 6.1 Measure 7 inches from the tip of the splash shield along the centerline and mark where the center of the sight hole should be. See Fig. 1 and Fig. 2. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 7 06/02/2021 f602861 A A. 7 inches Fig. 2, Using a Machinist’s Square for Marking the Center of the Hole 6.2 Using a hole saw, cut a 4-inch (approximately 100 mm) sight hole. See Fig. 3 and Fig. 4. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 8 6.3 Using a round file, or any other appropriate tool, deburr the edges of the drilled holes. 6.4 Go to step 8 7. To enlarge existing 2-inch holes on both the hood mounted splash shields to 4 inches, follow the steps below. 7.1 Locate the existing 2-inch hole. 05/27/2021 f602862 1 2 1. Splash Shield 2. 4-Inch Hole Saw Fig. 3, Drilling a 4-Inch Hole in the Splash Shield 05/27/2021 f602863 Fig. 4, 4″ Hole Drilled in RH Side Hood-Mounted Splash Shield 7.2 Using the 1-inch side of a machinist’s square, or any other suitable measuring tool or method, mark a perimeter of the 4 inches concentric to the existing hole. See Fig. 5. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 9 7.3 Align a 4-inch hole saw to the marked perimeter. With the drill tool set to rotate counterclockwise, carefully drill the hole. 7.4 Using a round file, or other appropriate tool, deburr the perimeter of the drilled holes. 05/27/2021 f602864 B A A. Existing hole (2 inches). B. Mark a perimeter 1-inch from the edge of the existing hole. Fig. 5, Marking a 4-Inch Perimeter Concentric to the Existing 2-Inch Hole 8. Remove the covers from the headlamp cavities at both sides. See Fig. 6. Leave them suspending on the harness. Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 10 NOTICE Only handle a halogen bulb by its connector. Oil from your fingers can damage the bulb. 9. Without unplugging the harness, remove the bulbs and set them aside. 10. Inspect the headlamp housing grommet. • If rubber grommets are present, replace them with foam grommets. Go to next step. • If foam grommets are present, go to step 12. 11. Replace the rubber grommets on both the headlamp assemblies with foam grommets as follows. 11.1 Remove the rubber grommets and discard them. See Fig. 7 and Fig. 8. 11/04/2019 f547043 Fig. 6, Headlamp Cavity Covers 11/04/2019 f547049 Fig. 7, Removing the Rubber Grommet 11/04/2019 f547050 Fig. 8, Rubber Grommet Removed 11.2 Insert the foam grommets into the headlamp housing. Push and place all the edges inside the housing, and ensure the foam does not interfere with the bulb mounting interface. See Fig. 9 and Fig. 10. 06/02/2021 f547044a Fig. 9, Installing a Foam Grommet 06/02/2021 f547045a Fig. 10, Foam Grommet Installed Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 11 13. Reinstall the four lamp cavity covers onto the hood. See Fig. 12. 11/04/2019 f547046 Fig. 11, Headlamp Bulb Installed with a Foam Grommet Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 12 12. Reinstall the four headlamp bulbs. See Fig. 11. 11/04/2019 f547051 Fig. 12, Lamp Cavity Covers Properly Installed • If warning labels are already present, go to step 16. • If warning labels are not present, go to next step. 15. Clean two spots and install the warning labels (part number 24-02029-000) on each side of the hood as shown in Fig. 13. 16. Reinstall the hood mounted splash shields at both sides. For instructions, refer to Group 88 of the New Cascadia Workshop Manual. 17. Close the hood. 11/04/2019 f547041 Fig. 13, Warning Label and Location (LH Side Shown, RH Side Similar) Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 13 14. Check for warning labels as shown in Fig. 13. 19. Clean a spot on the base label (Form WAR259), write recall number FL887 on a blank red completion sticker (Form WAR260), and attach it to the base label. 11/04/2019 f547047 OK OK Fig. 14, Correctly (LH) and Incorrectly (RH) Seated Headlamp Bulbs Daimler Trucks North America LLC Recall Campaign July 2021 FL887A NHTSA #21V-357 Transport Canada #2021-290 Page 14 18. Verify all four headlight bulbs are fully seated by looking through the headlamp lens from the front of the vehicle. See Fig 14. If not properly installed, remove and install them properly. *********************************************************************************************************************** SEOCONTENT-END