Recall FL-893 – Aluminum Battery Cable Failure – 2019-2022 Freightliner Cascadia P4, 2021 Western Star WH126, 2020 Western Star WJ121, & 2021-2022 Western Star 49X

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Amended Defect Information Report (Section 573.6) FL-893 Date of Submission: July 20, 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: 2019 Model Yr. End: 2022 Make: Freightliner, Western Star Model: Cascadia P4, 49X, 57X Production Dates: Begin: 04/28/2018 End: 06/14/2021 Type: Buses, Medium & Heavy Duty Vehicles Descriptive Information: Freightliner Cascadia trucks and Western Star vehicles equipped with aluminum battery cables. Number potentially involved: 122,192 Estimated percentage of involve with defect: Under 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the battery cable terminal at the frame connecting point may break resulting loss of electrical power and unintended engine shut down without warning. Basis for determining the population and how the population differs from other vehicles not subject to recall: Vehicles built with aluminum battery cables. If a noncompliance, provide the applicable FMVSS: N/A Describe the safety risk: Unintended engine shut down without warning may result in a vehicle being stalled on the roadway which could increase the risk of a vehicle crash. Identify any warning which can precede or occur: None If applicable, identify the manufacture of the defective or noncompliant component: Auto Kabel de Mexico SA de CV Parque Industrial, Av. Hermanos Escobar 7151, Omega, Ciudad Juárez, Chihuahua,32320 Navia Saul Sales Account Manager [email protected] Phone: 915.217.2253 Involved Components Component Name: Power cables Component Description: Positive and negative power cables Component Part Number: Multiple part numbers 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 January 2021, DTNA received a single field report of unintended vehicle shutdown while in motion due to a broken battery cable. In or about March 2021, DTNA received another field report of positive battery cable separation at the 90 degree frame terminal and promptly began an investigation by, among other things, seeking to identify potentially similar incidents and seeking supplier analysis. In April 2021, DTNA received a failed part analysis report from the supplier. As a result, DTNA reviewed relevant warranty rate data to assess the matter. In or about May 2021, DTNA’s cross-functional team was tasked to conduct a battery cable test evaluation. Test reports suggested that mating two incompatible galvanic materials, Aluminum and Brass, and not sealing them appropriately increases the likelihood of debris intrusion, which in turn may cause progressive damage to the weld joint area. However, at this time, DTNA lacked information sufficient to determine if a defect existed or in what population it existed. In or about June 2021, supplier process investigation revealed that the current procedure doesn’t involve preheating of the joint before application of the wrap and due to that, it may not achieve a required surface bond which would be enough to prevent debris intrusion. Field input disclosed that the largest portion of these events are occurring outside of warranty and parts are being replaced by customers with dealer made copper cables, further complicating DTNA’s effort to understand if there was a defect observed in the field and, if so, what was the population. That said, DTNA’s estimates indicated a rate of occurrence significantly below 1%. Despite the uncertainty and the low rate of occurrence, out of an abundance of caution, on June 21, 2021, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. July 20, 2021, upon final review of production dates, bookend dates were revised, and therefore DTNA adjusted the recall population. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject Aluminum battery cables on the affected vehicles will be inspected for corrosion and/or damage and will be repaired or replaced with Copper cables accordingly. 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: 08/23/2021 Planned Dealer Notification End Date: 08/23/2021 Planned Owner Notification Begin Date: 08/23/2021 Planned Owner Notification End Date: 08/23/2021 Manufacture’s identification code for this recall (if applicable): FL-893 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs

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Defect Information Report (Section 573.6) FL-893 Date of Submission: June 25, 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: 2019 Model Yr. End: 2022 Make: Freightliner, Western Star Model: Cascadia P4, 49X, WH126,WJ121 Production Dates: Begin: 04/28/2018 End: 06/02/2021 Type: Buses, Medium & Heavy Duty Vehicles Descriptive Information: Freightliner Cascadia trucks and Western Star vehicles equipped with aluminum battery cables. Number potentially involved: 122,056 Estimated percentage of involve with defect: Under 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the battery cable terminal at the frame connecting point may break resulting loss of electrical power and unintended engine shut down without warning. Basis for determining the population and how the population differs from other vehicles not subject to recall: Vehicles built with aluminum battery cables. If a noncompliance, provide the applicable FMVSS: N/A Describe the safety risk: Unintended engine shut down without warning may result in a vehicle being stalled on the roadway which could increase the risk of a vehicle crash. Identify any warning which can precede or occur: None If applicable, identify the manufacture of the defective or noncompliant component. Auto Kabel Involved Components Component Name: Power cables Component Description: Positive and negative power cables Component Part Number: Multiple part numbers 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 January 2021, DTNA received a single field report of unintended vehicle shutdown while in motion due to a broken battery cable. In or about March 2021, DTNA received another field report of positive battery cable separation at the 90 degree frame terminal and promptly began an investigation by, among other things, seeking to identify potentially similar incidents and seeking supplier analysis. In April 2021, DTNA received a failed part analysis report from the supplier. As a result, DTNA reviewed relevant warranty rate data to assess the matter. In or about May 2021, DTNA’s cross-functional team was tasked to conduct a battery cable test evaluation. Test reports suggested that mating two incompatible galvanic materials, Aluminum and Brass, and not sealing them appropriately increases the likelihood of debris intrusion, which in turn may cause progressive damage to the weld joint area. However, at this time, DTNA lacked information sufficient to determine if a defect existed or in what population it existed. In or about June 2021, supplier process investigation revealed that the current procedure doesn’t involve preheating of the joint before application of the wrap and due to that, it may not achieve a required surface bond which would be enough to prevent debris intrusion. Field input disclosed that the largest portion of these events are occurring outside of warranty and parts are being replaced by customers with dealer made copper cables, further complicating DTNA’s effort to understand if there was a defect observed in the field and, if so, what was the population. That said, DTNA’s estimates indicated a rate of occurrence significantly below 1%. Despite the uncertainty and the low rate of occurrence, out of an abundance of caution, on June 21, 2021, 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 Aluminum battery cables on the affected vehicles will be inspected for corrosion and/or damage and will be repaired or replaced with Copper cables accordingly. 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: 08/23/2021 Planned Dealer Notification End Date: 08/23/2021 Planned Owner Notification Begin Date: 08/23/2021 Planned Owner Notification End Date: 08/23/2021 Manufacture’s identification code for this recall (if applicable): FL-893 DTNA Representative; Larissa Stoffels Executive Manager, Vehicle Safety Compliance and Regulatory Affairs

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Amended Defect Information Report (Section 573.6) FL-893 Date of Submission: November 2, 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: 2019 Model Yr. End: 2022 Make: Freightliner, Western Star Model: Cascadia P4, 49X, 57X Production Dates: Begin: 04/28/2018 End: 06/14/2021 Type: Buses, Medium & Heavy Duty Vehicles Descriptive Information: Freightliner Cascadia trucks and Western Star vehicles equipped with aluminum battery cables. Number potentially involved: 122,192 Estimated percentage of involve with defect: Under 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On certain vehicles, the battery cable terminal at the frame connecting point may break resulting loss of electrical power and unintended engine shut down without warning. Basis for determining the population and how the population differs from other vehicles not subject to recall: Vehicles built with aluminum battery cables. If a noncompliance, provide the applicable FMVSS: N/A Describe the safety risk: Unintended engine shut down without warning may result in a vehicle being stalled on the roadway which could increase the risk of a vehicle crash. Identify any warning which can precede or occur: None If applicable, identify the manufacture of the defective or noncompliant component: Auto Kabel de Mexico SA de CV Parque Industrial, Av. Hermanos Escobar 7151, Omega, Ciudad Juárez, Chihuahua,32320 Navia Saul Sales Account Manager [email protected] Phone: 915.217.2253 Involved Components Component Name: Power cables Component Description: Positive and negative power cables Component Part Number: Multiple part numbers 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 January 2021, DTNA received a single field report of unintended vehicle shutdown while in motion due to a broken battery cable. In or about March 2021, DTNA received another field report of positive battery cable separation at the 90 degree frame terminal and promptly began an investigation by, among other things, seeking to identify potentially similar incidents and seeking supplier analysis. In April 2021, DTNA received a failed part analysis report from the supplier. As a result, DTNA reviewed relevant warranty rate data to assess the matter. In or about May 2021, DTNA’s cross-functional team was tasked to conduct a battery cable test evaluation. Test reports suggested that mating two incompatible galvanic materials, Aluminum and Brass, and not sealing them appropriately increases the likelihood of debris intrusion, which in turn may cause progressive damage to the weld joint area. However, at this time, DTNA lacked information sufficient to determine if a defect existed or in what population it existed. In or about June 2021, supplier process investigation revealed that the current procedure doesn’t involve preheating of the joint before application of the wrap and due to that, it may not achieve a required surface bond which would be enough to prevent debris intrusion. Field input disclosed that the largest portion of these events are occurring outside of warranty and parts are being replaced by customers with dealer made copper cables, further complicating DTNA’s effort to understand if there was a defect observed in the field and, if so, what was the population. That said, DTNA’s estimates indicated a rate of occurrence significantly below 1%. Despite the uncertainty and the low rate of occurrence, out of an abundance of caution, on June 21, 2021, DTNA reasonably decided to conduct a voluntary recall as set forth in this report. July 20, 2021, upon final review of production dates, bookend dates were revised, and therefore DTNA adjusted the recall population. November 2, 2021, due to parts availability, the recall release has been delayed and is expected to launch in late-February 2022. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The subject Aluminum battery cables on the affected vehicles will be inspected for corrosion and/or damage and will be repaired or replaced with Copper cables accordingly. 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: 02/25/2022 Planned Dealer Notification End Date: 02/25/2022 Planned Owner Notification Begin Date: 02/25/2022 Planned Owner Notification End Date: 02/25/2022 Manufacture’s identification code for this recall (if applicable): FL-893 DTNA Representative; Tiffani Torgeson Manager, Compliance and Regulatory Affairs

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Daimler Trucks North America LLC August 2021 FL893 Interim Recall Notice NHTSA #21V-481 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Aluminum Battery Cable Failure 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, and 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 Freightliner Cascadia; and Western Star 47X, 48X, 49X, and 57X vehicles manufactured April 28, 2018, through June 18, 2021. On certain vehicles, the battery cable terminal at the frame connecting point may break, resulting in the loss of electrical power and unintended engine shutdown without warning, increasing the risk of 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 numbers, 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 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 Truck North America LLC February 2022 FL893 NHTSA #21V-481 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Aluminum Battery Cable FailureThis notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is to inform you that in August of 2021, a letter was sent informing you that your vehicle was included in our Recall campaign titled FL893 Aluminum Battery Cable Failure. It has been determined that the Recall repair has been completed on your vehicle, and therefore your vehicle is no longer involved in this campaign. No further action is required for this Recall. 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 Daimler Truck 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 February 2022 FL893A-D NHTSA #21V-481 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Aluminum Battery Cable Failure 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, and 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 Freightliner Cascadia; and Western Star 47X, 48X, 49X, and 57X vehicles manufactured April 28, 2018, through June 18, 2021. On certain vehicles, the battery cable terminal at the frame connecting point may break, resulting in the loss of electrical power and unintended engine shutdown without warning, increasing the risk of crash. The affected battery cables will be replaced with copper battery cables. Repairs will be performed by Daimler Trucks North America authorized service facilities. 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 X 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 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 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

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Daimler Truck North America LLC February 2022 FL893 NHTSA #21V-481 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Aluminum Battery Cable Failure This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Daimler Truck North America LLC (DTNA), on behalf of its Freightliner Truck Division, and its wholly owned subsidiary, Western Star Truck Sales, Inc., has decided that a defect which relates to motor vehicle safety exists on specific model years 2019-2022 Freightliner Cascadia vehicles; and Western Star 47X RHD, 48X RHD, and 49X vehicles manufactured April 28, 2018, through June 11, 2021. On certain vehicles, the battery cable terminal at the frame connecting point may break, resulting in the loss of electrical power and unintended engine shutdown without warning, increasing the risk of crash. The affected battery cables will be replaced with copper battery cables. Repairs will be performed by Daimler Truck North America authorized service facilities. Repairs will be performed by Daimler Truck North America authorized service facilities. Please contact an authorized Daimler Truck 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 two to 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 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 Truck North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone Daimler Truck 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 Truck 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 Truck North America LLC dealer. Please speak with your Daimler Truck North America LLC authorized dealer concerning this matter Daimler Truck North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone

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Subject: Aluminum Battery Cable Failure Models Affected: Specific model years 2019-2022 Freightliner Cascadia vehicles; and Western Star 47X RHD, 48X RHD, and 49X vehicles manufactured April 28, 2018, through June 11, 2021. General Information Daimler Trucks North America LLC (DTNA), on behalf of its Freightliner Trucks Division, and its wholly owned subsidiary, Western Star Truck Sales, Inc., has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above. On certain vehicles, the battery cable terminal at the frame connecting point may break, resulting in the loss of electrical power and unintended engine shutdown without warning, increasing the risk of crash. The affected battery cables will be replaced with copper battery cables. There are approximately 141,000 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 FL893, 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. Battery Cable Part Number Lookup Instructions (FL893A, B, C, F):The part numbers of the aluminum cables, that need to be replaced, can be identified using the PartsPro application. Follow the steps below to identify the VIN specific aluminum cable part number(s), and refer to Table 2 in order to identify the correct copper cable(s) to be installed on each vehicle. • Open PartsPro using your DTNAConnect credentials. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 1 • The ‘Design Groups’ page will be displayed. Locate the ‘Search’ button on the upper right side of the tool bar, then select the button. See Fig. 2. 02/08/2022 f121125 Fig. 1, Entering Serial Number in PartsPro 02/08/2022 f121126 Fig. 2, Locating the Search Tool Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 2 • Enter the last 6 digits (serial number) of the vehicle identification number (VIN), then select the ‘GO’ button. See Fig. 1. • Type ‘(AL)’ in the ‘Part Description:’ box. Failure to type ‘(AL)’ exactly could result in non-consistent search results. See Fig. 3. 02/08/2022 f121127 B A C A. Select the ‘Contains’ radio button. B. Type ‘(AL)’ in the ‘Parts Description’ box. C. Select the ‘Seach Button.’ Fig. 3, Search Window Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 3 • The ‘Search’ window will be displayed. See Fig. 3. Select the ‘Contains’ radio button. Failure to select ‘Contains’ could result in non-consistent search results. • After the part number(s) are identified, refer to Table 2 to determine the correct replacement copper cable(s) for each vehicle. Vehicles will have up to a maximum of four cables replaced, depending on the population group. 02/08/2022 f121128 A A. Note the part numbers listed in the ‘Search Results’ tab. Fig. 4, Multiple Part Numbers Displayed in the Search Results Tab 02/08/2022 f121129 A A. Note the part number highlighted in the ‘Bill Of Material’ tab. Fig. 5, Part Number Highlighted in the Bill Of Material Tab Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 4 • Press the ‘SEARCH’ button. If multiple aluminum cable part numbers found, the results will be displayed in the ‘Search Results’ tab; see Fig. 4. If only one aluminum cable part number is found, PartsPro will open the parts list for the applicable bill of material (BOM), and highlight the aluminum cable part number for easy reference; see Fig. 5. Note the cable part number(s) being displayed. Campaign Number Part Description Part Number Qty. Per VIN FL893A Four copper cables, refer to Battery Cable Part Number Lookup Instructions above for part numbers See instructions 4 ea CLAMP 0000 BATT CA 23-13454-001 6 – 12 ea FL893B Three copper cables, refer to Battery Cable Part Number Lookup Instructions above for part numbers See instructions 3 ea CLAMP 0000 BATT CA 23-13454-001 9 – 17 ea FL893C Two copper cables, refer to Battery Cable Part Number Lookup Instructions above for part numbers See instructions 2 ea CLAMP 0000 BATT CA 23-13454-001 0 – 8 ea FL893D CABLE-POS,4/0,3/8 X M8 2 HOLE,112″ A66-02837-112 1 ea CLAMP 0000 BATT CA 23-13454-001 8 ea FL893E CA-BAT,NEG,4/0,3/8-3/8 A06-34490-072 1 ea CLAMP 0000 BATT CA 23-13454-001 5 – 10 ea FL893F One copper cable, refer to Battery Cable Part Number Lookup Instructions above for part numbers See instructions 1 ea CLAMP 0000 BATT CA 23-13454-001 0 – 5 ea FL893G CABLE-NEG,4/0,3/8X3/8 SHORT90 A06-91586-070 1 ea FL893A,B,D STUD-THREADED TIE MOUNT,0.625 (For Cascadia 116 ONLY) 23-13805-062 2 ea FL893A-G BLANK COMPLETION STICKER WAR260 1 ea Table 1 Daimler Trucks North America LLC Recall Campaign Page 5 February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. Table 1 – Replacement Parts for FL893 NOTE: See the cross-reference Table 2 below to determine the copper cable(s) part number Existing Al Part Number Replacement Cu Recall Part Number A66-11631-048 A66-12313-048 A66-11631-052 A66-12313-052 A66-11631-056 A66-12313-056 A66-11631-060 A66-12313-060 A66-11631-064 A66-12313-064 A66-11631-068 A66-12313-068 A66-11631-072 A66-12313-072 A66-11631-082 A66-12313-084 A66-15575-108 A66-17600-108 A66-15575-110 A66-17600-110 A66-15575-112 A66-17600-112 A66-15575-116 A66-17600-116 A66-15575-124 A66-17600-124 A66-15575-128 A66-17600-128 A66-15575-130 A66-17600-130 A66-15575-132 A66-17600-132 A66-15575-136 A66-17600-136 A66-15575-138 A66-17600-138 A66-15611-080 A66-19605-080 A66-15611-084 A66-19605-084 A66-15611-088 A66-19605-088 A66-15611-096 A66-19605-096 A66-15611-100 A66-19605-100 A66-15611-104 A66-19605-104 A66-15611-108 A66-19605-108 Table 2 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 3 – Labor Allowance Campaign Number Procedure Time Allowed (hours) SRT Code Corrective Action FL893A Replace four aluminum battery cables with copper cables 2.8 996-R125A 12-Repair Recall/Campaign FL893B Replace three aluminum battery cables with copper cables 2.0 996-R125B 12-Repair Recall/Campaign FL893C Replace two aluminum battery cables with copper cables 1.8 996-R125C 12-Repair Recall/Campaign FL893D,E Replace one aluminum battery cable with a copper cable 1.2 996-R125E 12-Repair Recall/Campaign FL893F,G Replace one aluminum battery cable with a copper cable 1.0 996-R125F 12-Repair Recall/Campaign FL893A-D BCA spinning stud repair 0.8 996-R125D 12-Repair Recall/Campaign Table 3 Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 6 Existing Al Part Number Replacement Cu Recall Part Number A66-09638-106 A66-02837-106 A66-09638-108 A66-02837-108 A66-09638-112 A66-02837-112 A66-09638-114 A66-02837-114 A66-09638-126 A66-02837-126 A66-09638-128 A66-02837-128 A66-09638-132 A66-02837-132 A66-09638-154 A66-02837-154 A66-09639-072 A06-34490-072 A66-09639-114 A06-34490-114 A66-09640-080 A06-93715-080 A66-09640-084 A06-93715-084 A66-09640-088 A06-93715-088 A66-09640-092 A06-93715-092 A66-09640-096 A06-93715-096 A66-09640-130 A06-93715-130 A66-10443-068 A06-91586-068 A66-10443-070 A06-91586-070 A66-10443-076 A06-91586-076 A66-10444-084 A66-06414-084 A66-11631-036 A66-12313-036 A66-11631-040 A66-12313-040 A66-11631-044 A66-12313-044 Table 2 – Existing Aluminum (Al) Battery Cable Part Number to Replacement Copper (Cu) Battery Cable Part Number Cross-Reference 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. FL-893-A, FL893-B, etc.). • In the Primary Failed Part Number field, enter 25-FL893-000. • 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. 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 Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 7 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 February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 8 Daimler Trucks North America LLC Recall Campaign February2022 FL893A-G NHTSA#21V-481 TransportCanada#2021-399 CopyofNoticetoOwners Subject:AluminumBatteryCableFailure FortheNoticetoU.S.Customers:ThisnoticeissenttoyouinaccordancewiththeNationalTrafficandMotor VehicleSafetyAct.FortheNoticetoCanadianCustomers:Thisnoticeissenttoyouinaccordancewiththe requirementsoftheMotorVehicleSafetyAct.Thisistoinformyouthatyourvehiclemaycontainadefectthat couldaffectthesafetyofaperson. DaimlerTrucksNorthAmericaLLC(DTNA),onbehalfofitsFreightlinerTrucksDivision,anditswhollyowned subsidiary, Western Star Truck Sales, Inc., has decided that a defect that relates to motor vehicle safety exists on specific model years 2019-2022 Freightliner Cascadia vehicles; and Western Star 47X RHD, 48X RHD, and 49X vehicles manufactured April 28, 2018, through June 11, 2021. Oncertainvehicles,thebatterycableterminalattheframeconnectingpointmaybreak,resultinginthelossof electricalpowerandunintendedengineshutdownwithoutwarning,increasingtheriskofcrash. Theaffectedbatterycableswillbereplacedwithcopperbatterycables.RepairswillbeperformedbyDaimler TrucksNorthAmericaauthorizedservicefacilities. PleasecontactanauthorizedDaimlerTrucksNorthAmericadealertoarrangetohavetheRecallperformedand toensurethatpartsareavailableatthedealership.Tolocateanauthorizeddealer,goto Daimler-TrucksNorthAmerica.com/contact-us/.Scrolldownto“LocateaDealer,”andselecttheappropriate brand.TheRecallwilltakeapproximatelytwotothreehoursandwillbeperformedatnochargetoyou.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. YoumaybeliableforanyprogressivedamagethatresultsfromyourfailuretocompletetheRecallwithina 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 furnishthatwillassistusinlocatingthepresentowner.Ifyouhaveleasedthisvehicle,Federallawrequiresthat youforwardthisnoticetothelesseewithin10days.Ifyouareasubsequentstagemanufacturer,Federallaw requires that you forward this notice to your distributors and retail outlets within five working days. If you have paidtohavethisrecallconditioncorrectedpriortothisnotice,youmaybeeligibletoreceivereimbursement. Pleaseseethereversesideofthisnoticefordetails. IfyouhavequestionsaboutthisRecall,pleasecontacttheWarrantyCampaignsDepartmentat(800)547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address DTNA.Warranty.Campaigns@Daimlertruck.com.FortheNoticetoU.S.Customers:Ifyouarenotabletohave thedefectremediedwithoutchargeandwithinareasonabletime,youmaywishtosubmitacomplainttothe Administrator,NationalHighwayTrafficSafetyAdministration,1200NewJerseyAvenue,SE.,Washington,DC 20590;orcalltheVehicleSafetyHotlineat(888)327-4236(TTY:800-424-9153);ortohttps://www.safercar.gov. FortheNoticetoCanadianCustomers:Ifyouwishtosubmitacomplaintaboutthisrecall,youcancontact TransportCanadaroadsafety,80rueNoel,Gatineau,QuebecJ8Z0A1orcall(800)333-0510. Weregretanyinconveniencethisactionmaycausebutfeelcertainyouunderstandourinterestinmotorvehicle safety. WARRANTYCAMPAIGNSDEPARTMENT Enclosure Page9 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 February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 10 Work Instructions Subject: Aluminum Battery Cable Replacement Models Affected: Specific model years 2019-2022 Freightliner Cascadia vehicles; and Western Star 47X RHD4,8 X RHD, and 49X vehicles manufactured April 28, 2018, through June 11, 2021. NOTE: Up to four of the main powernet battery cables, made of aluminum, will be replaced with cables made of copper. The four cables that may need to be replaced are: • Positive 4/0 cable routed from batteries to starter. • Positive 4/0 cable routed from batteries to battery cable access (BCA). • Negative 4/0 cable routed from batteries to flywheel housing. • Negative 4/0 cable routed from batteries to mega ground junction block (MGJB). See Table 4 for campaign group procedure page numbers. 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 11 FL893A – Replace Four Aluminum Cables IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. Campaign Group Battery Cables Replaced Page Number FL893A 4 11 FL893B 3 18 FL893C 2 22 FL893D 1 25 FL893E 1 29 FL893F 1 32 FL893G 1 34 FL893A-G, Spinning Stud Repair BCA Spinning Stud 36 Table 4, Campaign Group Procedure Page Numbers 4. Inspect each of the four main powernet battery cables to identify those made of aluminum. Aluminum cables can be identified as follows: • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 7. 01/14/2022 f547686 Fig. 6, Negative Battery Cable Connection at the Battery Post 11/08/2021 f547687 Fig. 7, Powernet Battery Cables Made of Aluminum Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 12 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, also remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 6. 5. Remove the two nuts that attach the two positive aluminum battery cables to the positive battery jumper cable, then disconnect the two positive aluminum battery cables from the positive battery jumper cable. See Fig. 8. 6. Remove the two nuts, then disconnect the two negative aluminum battery cables from the ground studs on the frame rail near the batteries. 01/21/2022 f547688 1 2 3 A A A. Aluminum cables to positive jumper cable connection. 1. Positive Jumper Cable 2. Negative Battery Cable 3. Negative Jumper Cable Fig. 8, Aluminum Cables to Positive Jumper Connection Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 13 IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 8. Remove the nut that attaches the positive aluminum battery cable to the positive terminal of the starter, then disconnect the positive aluminum battery cable from the starter. 08/25/2016 f546519 1 1. Battery Cable Connection Fig. 9, BCA Battery Cable (Engine-Side Frontwall) 11/10/2021 f547698 Fig. 10, Holding the BCA Stud Daimler Trucks North America LLC Recall Campaign Page 14 February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 IMPORTANT: Care must be taken to prevent the BCA studs from spinning within the BCA case, during the removal of nuts securing the battery cable. Do not use power tools when removing the nuts from the BCA studs. Hold the ends of the studs in the non-threaded area with vise grip pliers, or a similar tool, to avoid the stud from spinning within the BCA case during removal. Use a hand wrench to remove the nuts from BCA. If any of the BCA studs still spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 7. While holding the non-threaded tip of the BCA main power exterior stud with vise grip pliers, carefully remove the two nuts from the BCA studs using a hand wrench, then disconnect the positive aluminum battery connection at the BCA. See Fig. 9 and Fig. 10. If any of the BCA studs spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 10. Remove the bolt that attaches the negative aluminum battery cable to the mega ground junction block (MGJB), then disconnect the negative aluminum battery cable from the MGJB. See Fig. 12. 11. Remove the left-hand side cab-mounted splash shield as follows: 11.1 Open the hood. 11.2 From underneath the splash shield, remove the screw that attaches the splash shield to the frontwall mounting bracket. 11.3 From underneath the splash shield, remove the four nuts at the backing plates. 11/10/2021 f547689 Fig. 11, Aluminum Battery Cable Bolt at the Flywheel Housing 11/10/2021 f547690 Fig. 12, Bolt at the MGJB Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 15 9. Remove the negative aluminum battery cable bolt at the flywheel housing, then disconnect the negative aluminum battery cable. See Fig. 11. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 12. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cables. 13. Remove all four aluminum battery cables from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 14. Install the new copper battery cable of the same length as that of the respective aluminum cable removed. Follow the routing of the original aluminum cables, then secure each cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). 15. For Cascadia 116 vehicles only: NOTE: The positive 4/0 cable from the batteries to BCA routing, near the right side cab mount frame bracket, needs to be secured to the exposed thread portion of the two right side cab mount frame bracket bolts using push-on tie mounts (23-13805-062). Only the two center upper bolts on the right side cab mount frame bracket can be used. Some Cascadia 116 vehicles may already utilize the two push-on tie mounts, which can be used again, but only with the new tie straps (23-13476-000). Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 16 IMPORTANT: Use care to avoid damaging the rocker panel on the lower edge of the cab side when removing the splash shield. 11.4 Remove the splash shield by pulling it forward until it clears the rocker panel, then pull it to the side. 15.2 Secure the new copper positive 4/0 cable to the push-on tie mount using tie straps (23-13476-000). See Fig. 14. 01/20/2022 f547730 1 2 3 1. Fastener, Cab Mount Frame Bracket 2. Push-On Tie Mount 23-13805-062 3. Tie Strap 23-13476-000 Fig. 14, Copper Cable Secured Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 17 15.1 Install the two push-on tie mounts (23-13805-062) on the exposed thread portion of the two right side cab mount frame bracket bolts. See Fig. 13. 01/20/2022 f547729 Fig. 13, Push-On Tie Mounts Installed 16. Position the 29A battery cable on the BCA battery studs. Use two new stainless steel nuts (23-12612-008), apply a drop of LOCTITE® Blue 242 to the area of the studs where the tightened nuts will overlap. Install the washers and the new nuts. Hold the end of each stud with vise grip pliers, then tighten each nut with a 13 mm box end wrench to secure the newly installed copper cable to the BCA. Tighten the nuts 10 to 12 lbf·ft (14 to 16 N·m). 17. Connect each end of the new copper cables to the appropriate component using the original fasteners, then tighten the fasteners per the torque values listed in Table 5. Fastener Torque Value lbf·ft (N·m) Positive cable at the starter main terminal 18 to 20 (24 to 27) Positive cable at the BCA main input studs (use new stainless steel nuts) 10 to 12 (14 to 16) Positive cables at the battery posts 10 to 15 (14 to 20) Negative cable at the flywheel housing 59 (80) Negative cable at the MGJB 14 (18) Negative cables at the frame rail studs 14 (18) DK cable clamp nuts 11 (15) Table 5, Torque Values, Copper Cable Connections 18. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 19. Install the left-hand side cab-mounted splash shield as follows: 19.1 Position the splash shield so that the cab studs align with the splash shield holes. Install the two backing plates and the four nuts on the studs. Tighten the nuts 15 lbf·ft (20 N·m). 19.2 Install the screw that attaches the splash shield to the frontwall mounting bracket. 20. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). 21. Close the hood. 22. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893B – Replace Three Aluminum Cables 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 15. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 18 01/14/2022 f547686 Fig. 15, Negative Battery Cable Connection at the Battery Post 4. Inspect each of the four main powernet battery cables to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 16. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 11/08/2021 f547687 Fig. 16, Powernet Battery Cables Made of Aluminum Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 19 5. Remove the two nuts that attach the two positive aluminum battery cables to the positive battery jumper cable, then disconnect the positive aluminum battery cables from the positive battery jumper cable. See Fig. 17. 6. Remove the nut that attaches the negative aluminum battery cable to the ground stud, on the frame rail near the batteries, then disconnect the negative aluminum battery cable from the ground stud. IMPORTANT: Care must be taken to prevent the BCA studs from spinning within the BCA case, during the removal of nuts securing the battery cable. Do not use power tools when removing the nuts from the BCA studs. Hold the ends of the studs in the non-threaded area with vise grip pliers, or a similar tool, to avoid the stud from spinning within the BCA case during removal. Use a hand wrench to remove the nuts from the BCA. If any of the BCA studs still spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 7. While holding the non-threaded tip of the BCA main power exterior stud with vise grip pliers, carefully remove the two nuts from the BCA studs using a hand wrench, then disconnect the positive aluminum battery connection at the BCA. If any of the BCA studs spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 8. Remove the nut that attaches the positive aluminum battery to the positive terminal of the starter, then disconnect the positive aluminum battery connection at the starter. 9. Remove the bolt at flywheel housing and disconnect the negative aluminum battery cable. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 10. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cables. 01/21/2022 f547688 1 2 3 A A A. Aluminum cables to positive jumper cable connection. 1. Positive Jumper Cable 2. Negative Battery Cable 3. Negative Jumper Cable Fig. 17, Aluminum Cables to Positive Jumper Connection Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 20 11. Remove all three aluminum battery cables from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 12. Install the new copper battery cable of the same length as that of the respective aluminum cable removed. Follow the routing of the original aluminum cables, then secure each cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). 13. For Cascadia 116 vehicles only: NOTE: The positive 4/0 cable from the batteries to BCA routing, near the right side cab mount frame bracket, needs to be secured to the exposed thread portion of the two right side cab mount frame bracket bolts using push-on tie mounts (23-13805-062). Only the two center upper bolts on the right side cab mount frame bracket can be used. Some Cascadia 116 vehicles may already utilize the two push-on tie mounts, which can be used again, but only with the new tie straps (23-13476-000). 13.1 Install the two push-on tie mounts (23-13805-062) on the exposed thread portion of the two right side cab mount frame bracket bolts. See Fig. 18. 13.2 Secure the new copper positive 4/0 cable to the push-on tie mount using tie straps (23-13476-000). See Fig. 19. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 21 01/20/2022 f547729 Fig. 18, Push-On Tie Mounts Installed 01/20/2022 f547730 1 2 3 1. Fastener, Cab Mount Frame Bracket 2. Push-On Tie Mount 23-13805-062 3. Tie Strap 23-13476-000 Fig. 19, Copper Cable Secured 14. Position the 29A battery cable on the BCA battery studs. Use two new stainless steel nuts (23-12612-008), apply a drop of LOCTITE® Blue 242 to the area of the studs where the tightened nuts will overlap. Install the washers and the new nuts. Hold the end of each stud with vise grip pliers, then tighten each nut with a 13 mm box end wrench to secure the newly installed copper cable to the BCA. Tighten the nuts 10 to 12 lbf·ft (14 to 16 N·m). 15. Connect each end of the new copper cables to the appropriate component using the original fasteners, then tighten the fasteners per the torque values listed in Table 6. Fastener Torque Value lbf·ft (N·m) Positive cable at the starter main terminal 18 to 20 (24 to 27) Positive cable at the BCA main input studs (use new stainless steel nuts) 10 to 12 (14 to 16) Positive cables at the battery posts 10 to 15 (14 to 20) Negative cable at the flywheel housing 59 (80) Negative cables at the frame rail studs 14 (18) DK cable clamp nuts 11 (15) Table 6, Torque Values, Copper Cable Connections 16. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 17. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 22 18. Close the hood. 19. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893C – Right-Hand Drive (RHD), Replace Two Aluminum Cables 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 20. 4. Inspect each of the four main powernet battery cables to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 21. 01/14/2022 f547686 Fig. 20, Negative Battery Cable Connection at the Battery Post Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 23 11/08/2021 f547687 Fig. 21, Powernet Battery Cables Made of Aluminum IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 5. Remove the nut that attaches the positive starter aluminum battery cable to the positive battery jumper cable, then disconnect the positive starter aluminum battery cable from the positive battery jumper cable. 6. Remove the nut that attaches the negative aluminum battery cable to the ground stud, on the frame rail near the batteries, then disconnect the negative aluminum battery cable from the ground stud. This cable routes to the flywheel housing ground. 7. Remove the nut that attaches the positive aluminum battery connection to the positive terminal of the starter, then disconnect the positive aluminum battery connection from the starter. 8. Remove the bolt that attaches the negative aluminum battery cable to the flywheel housing, then disconnect the negative aluminum battery cable from the flywheel housing. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 9. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cables. 10. Remove the two aluminum starter battery cables from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 24 11. Install the new copper battery cable of the same length as that of the respective aluminum cable removed. Follow the routing of the original aluminum cables, then secure each cable using new clamps (23-13454- 001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). 12. Connect each end of the new copper cables to the appropriate component using the original fasteners, then tighten the fasteners per the torque values listed in Table 7. Fastener Torque Value lbf·ft (N·m) Positive cable at the starter main terminal 18 to 20 (24 to 27) Positive cables at the battery posts 10 to 15 (14 to 20) Negative cable at the flywheel housing 59 (80) Negative cables at the frame rail studs 14 (18) DK cable clamp nuts 11 (15) Table 7, Torque Values, Copper Cable Connections 13. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 14. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). 15. Close the hood. 16. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893D – Replace One Aluminum Positive 4/0 Cable Routed from Batteries to Battery Cable Access (BCA) NOTE: Vehicles that belong to FL893D require only ONE main powernet battery cable, made of aluminum, to be replaced with a cable made of copper. The cable needing to be replaced is the positive 4/0 cable routed from the batteries to the battery cable access (BCA). Aluminum cables have a larger outer diameter compared to the copper cables, and will have a label installed indicating it is an aluminum cable. 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 25 4. Inspect the positive 4/0 cable routed from the batteries to the BCA to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 23. 01/14/2022 f547686 Fig. 22, Negative Battery Cable Connection at the Battery Post 11/08/2021 f547687 Fig. 23, Powernet Battery Cables Made of Aluminum Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 26 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 22. 5. Remove the nut that attaches the BCA positive aluminum battery cable to the positive battery jumper cable connection at the batteries, then disconnect the BCA positive aluminum battery cable from the positive battery jumper cable. IMPORTANT: Care must be taken to prevent the BCA studs from spinning within the BCA case, during the removal of nuts securing the battery cable. Do not use power tools when removing the nuts from the BCA studs. Hold the ends of the studs in the non-threaded area with vise grip pliers, or a similar tool, to avoid the stud from spinning within the BCA case during removal. Use a hand wrench to remove the nuts from BCA. If any of the BCA studs still spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 6. While holding the non-threaded tip of the BCA main power exterior stud with vise grip pliers, carefully remove the two nuts from the BCA studs using a hand wrench, then disconnect the positive aluminum battery connection at the BCA. If any of the BCA studs spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. See Fig. 24 and Fig. 25. 08/25/2016 f546519 1 1. Battery Cable Connection Fig. 24, BCA Battery Cable (Engine-Side Frontwall) Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 27 IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 11/10/2021 f547698 Fig. 25, Holding the BCA Stud 7. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cable. 8. Remove the positive 4/0 cable, that is routed from the batteries to the BCA, from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 9. Install the new copper battery cable of the same length as that of the aluminum cable removed. Follow the routing of the original aluminum cable, then secure the cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). Tighten DK cable clamp nuts 11 lbf·ft (15 N·m). 10. For Cascadia 116 vehicles only: NOTE: The positive 4/0 cable from the batteries to BCA routing, near the right side cab mount frame bracket, needs to be secured to the exposed thread portion of the two right side cab mount frame bracket bolts using push-on tie mounts (23-13805-062). Only the two center upper bolts on the right side cab mount frame bracket can be used. Some Cascadia 116 vehicles may already utilize the two push-on tie mounts, which can be used again, but only with the new tie straps (23-13476-000). 10.1 Install the two push-on tie mounts (23-13805-062) on the exposed thread portion of the two right side cab mount frame bracket bolts. See Fig. 26. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 28 10.2 Secure the new copper positive 4/0 cable to the push-on tie mount using tie straps (23-13476-000). See Fig. 27. 01/20/2022 f547729 Fig. 26, Push-On Tie Mounts Installed 01/20/2022 f547730 1 2 3 1. Fastener, Cab Mount Frame Bracket 2. Push-On Tie Mount 23-13805-062 3. Tie Strap 23-13476-000 Fig. 27, Copper Cable Secured Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 29 11. Position the battery cable on the BCA battery studs. Use two new stainless steel nuts (23-12612-008), apply a drop of LOCTITE® Blue 242 to the area of the studs the tightened nuts will overlap. Install the washers and the new nuts. Hold the end of each stud with vise grip pliers and tighten each nut with a 13 mm box end wrench to secure the newly installed copper cable to the BCA. Tighten the nuts 10 to 12 lbf·ft (14 to 16 N·m). 12. Connect the new positive cable at the battery post. Tighten the nut 10 to 15 lbf·ft (14 to 20 N·m). 13. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 14. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). Tighten negative cable at the battery posts 10 to 15 lbf·ft (14 to 20 N·m). 15. Close the hood. 16. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893E – Replace One Aluminum negative 4/0 Cable Routed from the Battery Frame Stud to the Mega Ground Junction Block (MGJB) NOTE: Vehicles that belong to FL893E require only ONE main powernet battery cable, made of aluminum, to be replaced with a cable made of copper. The cable needing replaced is the negative 4/0 cable routed from the battery frame stud to the mega ground junction block (MGJB). Aluminum cables have a larger outer diameter compared to the copper cables, and will have a label installed indicating it is an aluminum cable. 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 28. 01/14/2022 f547686 Fig. 28, Negative Battery Cable Connection at the Battery Post Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 30 4. Inspect the negative 4/0 cable routed from the battery frame stud to the MGJB to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 29. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 11/08/2021 f547687 Fig. 29, Powernet Battery Cables Made of Aluminum 5. Remove the nut that attaches the negative 4/0 aluminum battery cable to the ground stud, on the frame rail near the batteries, then disconnect the negative 4/0 aluminum battery cable from the ground stud. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 31 6. Remove the fastener that attaches the negative aluminum battery cable to the MGJB, at the cab frontwall, then disconnect the negative aluminum battery cable from the MGJB. See Fig. 30. 7. Remove the left-hand side cab-mounted splash shield as follows: 7.1 Open the hood. 7.2 From underneath the splash shield, remove the screw that attaches the splash shield to the frontwall mounting bracket. 7.3 From underneath the splash shield, remove the four nuts at the backing plates. IMPORTANT: Use care to avoid damaging the rocker panel on the lower edge of the cab side when removing the splash shield. 7.4 Remove the splash shield by pulling it forward until it clears the rocker panel, then pull it to the side. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 8. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cable. 9. Remove the negative 4/0 cable routed from the battery frame stud to the MGJB. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 11/10/2021 f547690 Fig. 30, Bolt at the MGJB 10. Install the new copper battery cable of the same length as that of the aluminum cable removed. Follow the routing of the original aluminum cable, then secure the cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 32 11. Install one end of the negative cable on the MGJB, then install the other end of the cable on the frame rail stud. Tighten the negative cable fasteners 14 lbf·ft (19 N·m). 12. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 13. Install the left-hand side cab-mounted splash shield as follows: 13.1 Position the splash shield so that the cab studs align with the splash shield holes. Install the two backing plates and the four nuts on the studs. Tighten the nuts 15 lbf·ft (20 N·m). 13.2 Install the screw that attaches the splash shield to the frontwall mounting bracket. 14. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). Tighten negative cable at the battery posts 10 to 15 lbf·ft (14 to 20 N·m). 15. Close the hood. 16. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893F – Replace One Aluminum Positive 4/0 Cable Routed from the Batteries to the Starter NOTE: Vehicles that belong to FL893F require only ONE main powernet battery cable, made of aluminum, to be replaced with a cable made of copper. The cable needing to be replaced is the positive 4/0 cable routed from the batteries to the starter. Aluminum cables have a larger outer diameter compared to the copper cables, and will have a label installed indicating it is an aluminum cable. 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 31. 01/14/2022 f547686 Fig. 31, Negative Battery Cable Connection at the Battery Post Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 33 4. Inspect the positive 4/0 cable routed from the batteries to the starter to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 32. 5. Remove the nut that attaches the positive 4/0 aluminum battery cable to the positive battery jumper cable connection at the batteries, then disconnect the positive 4/0 aluminum battery cable from the positive battery jumper cable. 11/08/2021 f547687 Fig. 32, Powernet Battery Cables Made of Aluminum 6. Remove the nut that attaches the positive aluminum battery to the positive terminal of the starter, then disconnect the positive aluminum battery cable from the starter. IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • of the same length as the original battery cables, • routed the same way as the original cables, • using the same clipping points as the original battery cables. 7. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cable. 8. Remove the positive 4/0 cable, that is routed from the batteries to the starter, from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 9. Install the new copper battery cable of the same length as that of the aluminum cable removed. Follow the routing of the original aluminum cable, then secure the cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 34 10. Install each end of the new copper cable. At the starter main terminal of the positive cable, tighten the fastener 18 to 20 lbf·ft (24 to 27 N·m). At the battery posts of the positive cable, tighten the fastener 10 to 15 lbf·ft (14 to 20 N·m). 11. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 12. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). Tighten negative cable at the battery posts 10 to 15 lbf·ft (14 to 20 N·m). 13. Close the hood. 14. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. FL893G – Replace One Aluminum Negative 4/0 Cable Routed from the Battery Frame Stud to the Flywheel Housing NOTE: Vehicles that belong to FL893G require only ONE main powernet battery cable, made of aluminum, to be replaced with a cable made of copper. The cable needing replaced is the negative 4/0 cable routed from the battery frame stud to the flywheel housing. Aluminum cables have a larger outer diameter compared to the copper cables, and will have a label installed indicating it is an aluminum cable. 1. Check the base label (Form WAR259) for a completion sticker for FL893 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next step. 2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 3. Remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). See Fig. 33. 01/14/2022 f547686 Fig. 33, Negative Battery Cable Connection at the Battery Post Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 35 4. Inspect the negative 4/0 cable routed from the battery frame stud to the flywheel housing to identify those made of aluminum. Aluminum cables can be identified as follows. • The aluminum 4/0 cables have a larger outer diameter than the copper 4/0 cables. • The aluminum 4/0 cables are attached with a yellow label on each end indicating they are made of aluminum. See Fig. 34. 5. Remove the nut that attaches the negative 4/0 aluminum battery cable to the ground stud, on the frame rail near the batteries, then disconnect the negative 4/0 aluminum battery cable from the ground stud. 6. Remove the negative aluminum battery cable bolt at the flywheel housing, then disconnect the negative aluminum battery cable. See Fig. 35. 11/08/2021 f547687 Fig. 34, Powernet Battery Cables Made of Aluminum 11/10/2021 f547689 Fig. 35, Aluminum Battery Cable Bolt at the Flywheel Housing Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 36 IMPORTANT: The battery cable length and routing may vary among vehicles. The replacement copper cables must be: • Of the same length as the original battery cables, • Routed the same way as the original cables, • Using the same clipping points as the original battery cables. 7. Make notes, or take pictures of the original cable routing and clipping points. Remove and discard all the clamps, tie straps, tie blocks, and clipping hardware securing the aluminum cable. 8. Remove the negative 4/0 cable, that is routed from the battery frame stud to the flywheel housing, from the vehicle. IMPORTANT: As the new copper cables have a smaller outer diameter, the existing aluminum cable clamps must not be used on the copper cables. Discard the existing clamps used on the aluminum cables. Use the new copper cable clamp (23-13454-001) in order to properly secure copper battery cables, and prevent rubbing and chaffing. 9. Install the new copper battery cable of the same length as that of the aluminum cable removed. Follow the routing of the original aluminum cable, then secure the cable using new clamps (23-13454-001), new tie straps (23-13476-000), and new dual tie blocks (TYC DCT110HIR). Battery cable clipping points should be placed at minimum spacing of 2 inches (5.1 cm) and maximum spacing of 8 inches (20.3 cm). 10. Install the new copper negative cable at the flywheel housing. Tighten the bolt 59 lbf·ft (80 N·m). 11. Install the new copper negative cable at the frame rail stud. Tighten the bolt 14 lbf·ft (19 N·m). 12. As needed, lightly coat the cable end terminals with red enamel, and the battery terminals with dielectric grease. 13. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). Tighten negative cable at the battery posts 10 to 15 lbf·ft (14 to 20 N·m). 14. Close the hood. 15. Clean a spot on the base label (Form WAR259), write the recall number, FL893, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed. BCA Spinning Stud Repair IMPORTANT: This procedure applies to the two main power exterior studs only, and should not be used for other repairs. BCA Removal 1. If not previously done, remove the negative battery cable from the battery post. If equipped with auxiliary batteries, remove the negative battery cable(s) from the auxiliary battery post(s). 2. Remove the electronics bay cover and the passenger-side lower dash cover. Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 37 08/25/2016 f546520 1 1. BCA Electrical Connectors Fig. 36, BCA Electrical Connectors 3. Remove the four BCA electrical connectors located on the cab-side frontwall, below the central gateway. See Fig. 36. 4. Remove the three cab-side battery cable nuts and washers, then disconnect the battery cables. See Fig. 37. 08/25/2016 f546518 1 1. Battery Cables Fig. 37, Three BCA Battery Cables (Cab-Side Frontwall) Daimler Trucks North America LLC Recall Campaign Page 38 February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 IMPORTANT: Care must be taken to prevent the BCA studs from spinning within the BCA case, during the removal of nuts securing the battery cable. Do not use power tools when removing the nuts from the BCA studs. Hold the ends of the studs in the non-threaded area with vise grip pliers, or a similar tool, to avoid the stud from spinning within the BCA case during removal. Use a hand wrench to remove the nuts from BCA. If any of the BCA studs still spin, repair the spinning stud. For instructions, refer to BCA Spinning Stud Repair on page 36. 5. From the engine-side frontwall, carefully hold the non-threaded portion of stud with pliers and use a hand wrench to remove the two nuts from the battery cable studs (if not previously removed), then disconnect the battery cable. Also remove any optional cables that also may be attached to the exterior of the BCA. See Fig. 38 and Fig. 39. 08/25/2016 f546519 1 1. Battery Cable Fig. 38, BCA Battery Cable (Engine-Side Frontwall) 11/10/2021 f547698 Fig. 39, Holding the BCA Stud Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 39 NOTE: One of the BCA assembly mounting nuts is located behind the battery contactor solenoid. A shorthandled wrench with a ½ inch socket may be required to remove the nut. 6. Remove the four stud nuts and washers attaching the BCA assembly to the engine-side frontwall. SeeFig. 40. 08/25/2016 f546522 1 1 1 A A. One stud nut is obscured from view by the battery contactor solenoid. 1. BCA Stud Nuts Fig. 40, BCA Mounting Stud Nuts 7. Remove the BCA assembly from the frontwall. 8. To secure the studs during the spinning stud repair procedure, install a washer and a nut onto each of the BCA main power exterior studs, torque nuts to 10 to 12 lbf·ft (14 to 16 N·m). Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 40 NOTE: Two holes will be drilled in the BCA back cover directly behind the two main power exterior studs. Care must be taken to ensure holes are drilled in the correct location. 9. Layout and drill two holes in the plastic BCA back cover as follows: Starting at the left lower corner of the back cover, mark locations at 2–½ inches and 3–½ inches. Place an intersecting mark at 3/8 inch from the outer edge. These two intersecting marks should line up with the two main power exterior studs. Using a 3/16 inch drill bit, drill the outer plastic cover at the two intersecting marks. The plastic cover is approximately 1/16 inches thick and is easily drilled. Do not drill into the metal studs that are approximately 3/8 inch below the plastic cover. See Fig. 41 and Fig. 42. 10. Using fast dry two-part epoxy with mixing tube applicator such as JB Weld Clearweld™, or Loctite Instant Mix Epoxy™, create an epoxy test patch on a flat/level piece of scrap material in order to gauge the amount of pressure (or effort)/time is required to apply enough epoxy to fill a space 3/4 × 3/4 × 3/8 inches high. See Fig. 43 and Fig. 44. 11/10/2021 f547691 Fig. 41, Marking 2–½ inches and 3–½ inches from the Lower Corner 11/10/2021 f547692 Fig. 42, Drilled Holes 11/10/2021 f547693 Fig. 43, JB Weld Clearweld™ 11/10/2021 f547694 Fig. 44, Loctite Instant Mix Epoxy™ Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 41 11. Place the BCA on a level surface in preparation for applying epoxy. Apply the epoxy into each hole and fill with enough epoxy to fill a space 3/4 × 3/4 × 3/8 inches similar to the test patch on step 10. Wipe excess glue from the BCA case and cover the two holes with electrical tape. Leave the BCA on a level surface and allow time for epoxy to set before installing the BCA, typically minimum of 5 minutes, use test patch to determine when epoxy has set firm. See Fig. 45, Fig. 46 and Fig. 47. 11/10/2021 f547695 Fig. 45, Setting the BCA on a Level Surface 11/10/2021 f547696 Fig. 46, Epoxy Application 11/10/2021 f547697 Fig. 47, Covering the Two Holes With Electric Tape Daimler Trucks North America LLC Recall Campaign February 2022 FL893A-G NHTSA #21V-481 Transport Canada #2021-399 Page 42 BCA Installation NOTE: The BCA mounting studs on the frontwall are designed to allow for slight movement. 1. Position the BCA on the four mounting studs on the engine-side frontwall. Install four mounting nuts and washers, and tighten the nuts to 10 to 12 lbf·ft (14 to 16 N·m). 2. Remove the two nuts and washers installed for the spinning stud repair, then position the 29A battery cable on the BCA battery studs. Use two new stainless steel nuts (23-12612-008), apply a drop of LOCTITE® Blue 242 to the area of the studs where the tightened nuts will overlap. Install the washers and the new nuts. Hold the end of each stud with vise grip pliers, then tighten each nut with a 13 mm box end wrench to secure the newly installed copper cable to the BCA. Tighten the nuts 10 to 12 lbf·ft (14 to 16 N·m). See Fig. 48. 11/10/2021 f547698 Fig. 48, Holding Stud and Tightening with Wrench 3. Install any optional cables previously removed from the BCA and torque the nuts to 10 to 12 lbf·ft (14 to 16 N·m). 4. From the cab-side frontwall, position the three battery cables on the battery studs, then install the washers and nuts. Tighten the nuts to 10 to 12 lbf·ft (14 to 16 N·m). 5. Connect the four BCA electrical connectors. 6. Install the dash panels. 7. Install the negative battery cable on the battery post. If equipped with auxiliary batteries, install the negative battery cable(s) on the auxiliary battery post(s). 8. Continue with the respective aluminum cable repair procedure above.

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The information contained in this letter supercedes and supplements any related policies and procedures in any previously released bulletins, the Warranty Manual, and/or previously released letters. Failure to read or distribute this letter will not exempt addressees from compliance with the information contained herein. Page 1 of 1 Daimler Trucks North America LLC REF #: ICI21-024 Effective: 08/17/2021 Release: 08/17/2021 SUBJECT: FL893 – Interim Recall Notice This letter is to inform you that an interim recall notice is being sent to affected customers for recall FL893 ~ Aluminum Battery Cable Failure. The interim notices will be mailed by 08/23/2021. 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 August 2021 FL893 Interim Recall Notice NHTSA #21V-481 IMPORTANT SAFETY RECALL See enclosed VIN list Subject: Aluminum Battery Cable Failure 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, and 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 Freightliner Cascadia; and Western Star 47X, 48X, 49X, and 57X vehicles manufactured April 28, 2018, through June 18, 2021. On certain vehicles, the battery cable terminal at the frame connecting point may break, resulting in the loss of electrical power and unintended engine shutdown without warning, increasing the risk of 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 numbers, 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 Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone The information contained in this letter supercedes and supplements any related policies and procedures in any previously released bulletins, the Warranty Manual, and/or previously released letters. Failure to read or distribute this letter will not exempt addressees from compliance with the information contained herein. Page 1 of 1 Daimler Trucks North America LLC REF #: ICI21-024 Effective: 08/17/2021 Release: 08/17/2021 SUBJECT: FL893 – Interim Recall Notice Cette lettre a pour but de vous informer qu’un avis de rappel volontaire provisoire a été envoyé aux clients concernés par l’avis de rappel volontaire FL893 – Défaillance de câble de batterie en aluminium. Les avis provisoires seront envoyés le 23 Août 2021. Une copie vous est fournie à titre de référence. Cet avis est uniquement destiné à votre information. Aucune action n’est requise des clients ni des concessionnaires. Si des clients posent des questions, veuillez leur demander de consulter l’avis provisoire. Si vous avez des questions ou avez besoin de plus de renseignements, veuillez communiquer avec le service des campagnes de garantie en soumettant une demande via le lien WSC sur 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 Août 2021 FL893 Avis de rappel intermédiaire Transports Canada nº 2021-399 Objet : Défaillance de câble de batterie en aluminium Le présent avis vous est envoyé conformément aux exigences de la Loi sur la sécurité automobile. La présente a pour but de vous informer que votre véhicule est susceptible d’avoir un défaut qui pourrait porter atteinte à la sécurité humaine. Au nom de sa division Freightliner Trucks Division et de sa filiale en propriété exclusive Western Star Trucks Sales Inc., Daimler Trucks North America LLC (DTNA) a déterminé qu’une défectuosité liée à la sécurité des véhicules à moteur existe sur certains véhicules Freightliner Cascadia et Western Star modèles 47X, 48X, 49X et 57X des années modèles 2019 à 2022 construits entre le 28 avril 2018 et le 18 juin 2021. Sur certains véhicules, la borne du câble de batterie au point de connexion du châssis peut se rompre, ce qui pourrait entraîner une perte d’alimentation électrique et un arrêt involontaire du moteur sans avertissement, augmentant le risque d’accident. Ceci est le premier de deux avis que vous recevrez à ce sujet. Le but de cette lettre est de vous informer d’un rappel à venir pour corriger le problème mentionné ci-dessus. Daimler Trucks prépare actuellement la fourniture des pièces de remplacement. Aucune action n’est nécessaire pour l’instant. Le deuxième avis vous informera quand la solution définitive pour y remédier sera disponible. Lorsque vous recevez le deuxième avis, veuillez communiquer avec votre concessionnaire autorisé Daimler Trucks North America, afin de prendre les dispositions nécessaires pour le rappel de votre véhicule. Si vous n’êtes pas le propriétaire du ou des véhicules dont les numéros d’identification apparaissent sur l’avis de rappel, veuillez retourner l’avis au Service des campagnes de garanties avec tous les renseignements dont vous disposez qui pourraient nous aider à identifier le propriétaire actuel. Le loueur est également tenu par la loi fédérale de faire parvenir cet avis au locataire dans les 10 jours. Si vous êtes un fabricant secondaire, la loi fédérale exige que vous fassiez suivre cet avis à vos distributeurs et détaillants dans les cinq jours ouvrables. Si vous avez des questions sur cet avis de rappel, veuillez communiquer avec le Service des campagnes de garantie au 1-800-547-0712 de 7 h à 16 h, heure du Pacifique, du lundi au vendredi ou par courriel à [email protected]. Pour toute autre question, vous pouvez communiquer avec le centre d’assistance à la clientèle en composant le 1-800-385-4357. Si vous avez une préoccupation en matière de sécurité concernant ce rappel, vous êtes invités à communiquer avec Transports Canada – Sécurité routière au 80, rue Noël, Gatineau, Québec, J8Z 0A1 ou composer le 1-800-333-0510. Nous sommes désolés pour tout inconvénient pouvant résulter de cette activité, mais nous sommes certains que vous comprenez notre intérêt dans la sécurité des véhicules motorisés. SERVICE DES CAMPAGNES DE GARANTIE Pièce jointe Daimler Trucks North America LLC Service des campagnes de garantie P.O. Box 4090 Portland, OR 97208-4090 Téléphone : 1-800-547-0712

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