FL907 Power Stud May Electrically Arc to Bulkhead – 2017-2019 Western Star 4700, 4900, 5700, & 6900 Trucks

November 12, 2021 NHTSA CAMPAIGN NUMBER: 21V882000

Power Stud May Electrically Arc to Bulkhead

An electrical arc can increase the risk of a fire.

 

NHTSA Campaign Number: 21V882

Manufacturer Daimler TruckseBay logo North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 7,128

 

Summary

Daimler TruckseBay logo North America LLC (DTNA) is recalling certain 2017-2019 Western StareBay logo 4700, 4900, 5700, and 6900 trucks. The affected trucks have a power stud that passes through the bulkhead. In certain circumstances, the power stud may contact the bulkhead and result in an electrical arc.

 

Remedy

Dealers will replace the pass-through power studs, free of charge. Owner notification letters were mailed January 7, 2022. This recall supersedes previous recall number 18V-191. Vehicles previously inspected and considered complete under 18V-191 will need to return for the new remedy. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-907.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check for Daimler Trucks North America Recalls

 


Western Star
Western Star

 


Subject: Western Star Power Cable Studs

Models Affected: Specific model years 2017-2019 Western StareBay logo 4700, 4900, 5700, and 6900 model vehicles manufactured September 12, 2016, through February 6, 2018.

 

General Information

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

On certain vehicles, the bulkhead pass through power cable studs with an attached gasket seal may not protrude through the bulkhead adequately. If improperly installed, the power cable studs may contact the bulkhead, resulting in potential arcing, which may increase the risk of a fire.

The bulkhead pass through power cable studs will be replaced.

There are approximately 9,293 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 FL907, a list of the customers and vehicle identification numbers will be available on DTNAConnect. Please refer to this list when ordering parts for this recall.

Table 1 – Replacement Parts for FL907

Campaign NumberKit NumberPart DescriptionPart NumberQty.
FL907AN/A(1/4) STUD-ASSY,GASKET,JEI28SP0797RA23-14242-0062 ea
(1/4) STUD-ASSY,GASKET,JEI28SP0797BA23-14242-0071 ea
NUT MOUNT,3/4-16UNF,NYLON,RED23-13770-0002 ea
NUT MOUNT,3/4-16UNF,NYLON,BLK23-13770-0011 ea
BLANK COMPLETION STICKERWAR2601 ea
FL907BN/A(3/8) STUD-ASSY,GASKET,JEI28SP0339A23-14242-0042 ea
(3/8) STUD-ASSY,GASKET,JEI28SP0338A23-14242-0051 ea
NUT MOUNT,3/4-16UNF,NYLON,RED23-13770-0002 ea
NUT MOUNT,3/4-16UNF,NYLON,BLK23-13770-0011 ea
BLANK COMPLETION STICKERWAR2601 ea

 

Power Cable Stud Replacement

1. Check the base label (Form WAR259) for a completion sticker for FL907 (Form WAR261) 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. Disconnect the batteries.

4. Open the hood.

5. Locate the power cable stud connectors on the frontwall. Pull back the cover on the power cable stud connector.
See Fig. 1.

 

6. Loosen the dash, then move it back enough to access the frontwall power terminals. For instructions, refer to Group 60 of the Western StareBay logo Workshop Manual.

 

NOTE: It is not necessary to disconnect wiring or air lines to access the terminals. When moving the dash, be careful not to over-stretch the wire harnesses and/or the air lines.

7. Disconnect the cables from the terminals inside the cab. See Fig. 2.

 

8. Disconnect the cables from the terminals on the outside of the frontwall.

9. Remove the plastic nuts and the studs.

10. Remove the old power cable studs, then replace them with the new power cable studs.

IMPORTANT: Replacement studs must be installed with the plastic nut on the inside of the frontwall, regardless of how they were installed prior to this repair.

11. Fully seat each stud in the square hole.

 

12. Tighten the plastic nuts 80 to 98 lbf·in (904 to 1107 N·cm). Make sure at least one thread is exposed past the plastic nut. See Fig. 3 and Fig. 4.

 

13. Connect the cables to the terminals on the outside of the frontwall, then install the nuts.

  • For 1/4-inch studs, tighten the nuts 48 to 58 lbf·in (542 to 655 N·cm).
  • For 3/8-inch studs, tighten the nuts 96 to 118 lbf·in (1085 to 1333 N·cm).

14. Connect the cables to the terminals inside the cab, then install the nuts.

  • For 1/4-inch studs, tighten the nuts 48 to 58 lbf·in (542 to 655 N·cm).
  • For 3/8-inch studs, tighten the nuts 96 to 118 lbf·in (1085 to 1333 N·cm).

15. Install the dash. For instructions, refer to Group 60 of the Western StareBay logo Workshop Manual.

16. Clean a spot on the base label (Form WAR259), write the recall number, FL907, on a blank red completion sticker (Form WAR260), and attach it to the base label, indicating this work has been completed.

 


Chronology :

In or about March 2018, DTNA recalled certain Western StareBay logo vehicles (DTNA Recall No. FL766, NHTSA Recall No. 18V-191). The recall remedy involved, among other things, an inspection of the pass through power stud for clearance to the bulkhead, and if required, replacement of the appropriate component.

Throughout 2018 and 2019, DTNA met with NHTSA’s Office of Defects Investigation (ODI) in monthly, voluntary SEL meetings where, among other things, DTNA discussed with ODI data and analysis regarding post-recall incidents in DTNA Recall No. FL766/NHTSA Recall No. 18V-191, and the adequacy of the inspect and replace approach was discussed. DTNA continued in good faith to believe the remedy adequate and otherwise did not present further unreasonable risk to safety, and ODI concurred.

Later, in or about April 2021, DTNA decided to reconsider the inspect and replace remedy approach given certain new data (identified below), opened an investigation, and added that new investigation to the ODI SEL spreadsheet for discussion with ODI during continued monthly SEL discussions with the agency, as required by the agency’s December 2020 consent order.

In or about April to late September 2021, DTNA analyzed plant quality data, field service information, warranty data, and inspected exemplar vehicles. DTNA’s analysis identified the potential that field operator routine maintenance/cleaning using high pressure power-washing equipment could be introducing additional water intrusion risk that was not reasonably foreseen in prior analysis in DTNA Recall No. FL766/NHTSA Recall No. 18V-191, or in discussions with NHTSA ODI, as well as the possibility that field technicians were encountering inspection challenges that were, likewise not reasonably foreseen.

Chronology continued on PDF copy

 


12 Affected Products

Vehicles

MAKEMODELYEAR
WESTERN STAReBay logo47002017-2019
WESTERN STAReBay logo49002017-2019
WESTERN STAReBay logo57002017-2019
WESTERN STAReBay logo69002017-2019

 


11 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-21V882-5359.pdf 144.78KB

 


Recall Acknowledgement

RCAK-21V882-7658.pdf 645.629KB

 


Defect Notice 573 Report

RCLRPT-21V882-5504.PDF 215.995KB

 


Miscellaneous Document

RMISC-21V882-1512.pdf 827.389KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V882-6369.pdf 534.626KB

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V882-9619.pdf 180.296KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V882-6079.pdf 144.78KB

 


Recall 573 Report – January 18, 2022

RCLRPT-21V882-1733.PDF 215.991KB

 


Recall Quarterly Report #1, 2022-1

RCLQRT-21V882-1890.PDF 211.158KB

 


Recall Quarterly Report #2, 2022-2

RCLQRT-21V882-8865.PDF 211.264KB

 


Recall Quarterly Report #3, 2022-3

RCLQRT-21V882-6002.PDF 211.351KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V882&docType=RCL

 


 

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