FL966 Modulator Valve Corrosion May Cause Brake Pull – 2017-2023 Freightliner Cascadia, 2022-2023 Western Star 47X, Western Star 49X, & 2022 Freightliner 114SD

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February 10, 2023 NHTSA CAMPAIGN NUMBER: 23V073000

Modulator Valve Corrosion May Cause Brake Pull

Brakes that pull to one side may cause a sudden change in vehicle direction, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V073

Manufacturer Daimler Trucks North America, LLC

Components ELECTRONIC STABILITY CONTROL, SERVICE BRAKES, AIR

Potential Number of Units Affected 69,246

 

Summary

Daimler Trucks North America, LLC (DTNA) is recalling certain 2017-2023 Freightliner Cascadia, 2022-2023 Western Star 47X, Western Star 49X, and 2022 Freightliner 114SD vehicles. The brake modulator valves on the front axle may corrode and cause the vehicle to pull to the affected side during braking initiated by Electronic Stability Control (ESC) or Roll Stability Control (RSC).

 

Remedy

Dealers will replace the front brake modulator valves, free of charge. Owner notification letters were mailed October 13, 2023. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL966.

 

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.nhtsa.gov.

 

Check for Daimler Trucks North America Recalls

 


Subject: Brake Modulator Valves

Models Affected: Specific model years 2017-2022 Freightliner 114SD, and Cascadia; and Western Star 47X, and 49X vehicles manufactured June 28, 2016, through April 8, 2022.

 

General Information

Daimler Truck North America LLC (DTNA), on behalf of its Freightliner Trucks Division, and 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 the affected vehicles, the brake modulator valves on the front axle may corrode, which during a braking event initiated by Electronic Stability Control (ESC) or Roll Stability Control (RSC), may result in full system pressure applied to one front wheel end causing a brake pull differential in braking force. A full system pressure applied to one front wheel end could lead to a brake pull resulting in a sudden change in vehicle direction due to uneven braking on the front axle increasing the risk of a crash.

A Daimler Truck North America authorized service facility will inspect and replace the brake modulator valves as required.

There are approximately 90,000 vehicles involved in this campaign.

REVISION: The work instruction has been updated to include additional information about the special tool needed for repair.

 

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).

 


Daimler Truck North America LLC
Updated Chronology – September 25, 2023

Starting in or around September 2022, based upon information gleaned from a different population of vehicles (those equipped with ACC), DTNA investigated whether non-ACC-equipped vehicles could have similar brake pull events. Initial indications, testing, and engineering judgment were that they would not. However in late October 2022, DTNA received a first indication from a driver that a vehicle in this population of vehicles suffered a brake pull. This conflicted DTNA’s indication that this population would not be affected by brake pulls, so in late October 2022, DTNA expanded its investigation, including interviewing drivers and running further tests.

On February 6 2023, DTNA received the first corroboration, a test result under controlled conditions, indicating a possibility of a sudden unexpected brake pull during rare conditions within ESC and RSC events, depending on a number of other factors including environment, speed, driving conditions, and level of valve blockage.

Despite the fact that DTNA has no evidence of field events other than the one driver in October 2022 asserting it happened, and despite the fact that the brake pull differential was not determined to the same degree as was reported during an ACC event, on February 6, 2023, out of abundance of caution, DTNA decided to initiate a new voluntary safety recall to campaign all vehicles equipped with painted and unpainted front brake modulator valves, covering the separate population that are not equipped with ACC.

On February 16, 2023, DTNA reviewed records and amended the population. On March 21, 2023 amended manufacturing dates to match model and owner letter table.

On September 25, 2023 DTNA updated the description of the remedy campaign to reflect prioritization of repairs for vehicles currently registered in certain states where road salt is regularly used in the winter.

 

FL966B – Front Modulator Valve Inspection

1. Check the base label (Form WAR259) for a completion sticker for FL966 (Form WAR260), indicating this work has been done. The base label is usually located on the passenger-side door, about 12 inches (30 cm)below the door latch. If a completion sticker is present, no work is needed. If a completion sticker is not present, proceed to the next step.

2. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.

3. Open the hood.

NOTE: Both the left- and right-hand modulator valves must be inspected. If either one of the modulator valves is bad, replace both modulator valves.

4. Remove the connector from the valve, and inspect the part number underneath the connector. See Fig. 1.
Good part numbers → 472 196 046 0 and 472 196 051 0
Bad part numbers → 472 196 025 0 and 472 196 037 0

• If the part numbers are good, install the connector. Clean a spot on the base label (Form WAR259), and attach a campaign completion sticker for FL966 (Form WAR260), indicating this work has been completed.

• If at least one of the part numbers is bad, go to the replacement procedure for the specified group, and replace both the modulator valves.

 

FL966A, B – Front Modulator Valve Replacement

NOTE: Both the left- and right-hand modulator valves must be replaced.

1. Locate the modulator valve on the front-left frame rail, behind the wheel. See Fig. 2.

2. Use the flat end of a screwdriver to disconnect the modulator valve electrical connector located on the front side of the frame rail, above the front axle. See Fig. 3.

3. Remove the antilock braking system (ABS) zip tie from the modulator mounting bolt. See Fig. 4

4. Use special tool (NQ307001-1) supplied in special tool kit NQ307001, referenced in Tool Letter 18 TL-15, to disconnect the plastic air line from the modulator valve. See Fig. 5 and Fig. 6.

5. Use a 7/8-inch wrench to remove the quick-connect fitting from the modulator. See Fig. 7.

6. Use a 7/8-inch wrench to remove the threaded air line that connects the modulator to the brake chamber. See Fig. 8.

7. Use a 23-mm wrench to loosen the brake chamber air line fitting on the modulator valve. See Fig. 9.

8. Use a 1/2-inch socket wrench to remove the two modulator valve mounting bolts, then remove the modulator valves from the vehicle.

9. Use a 23-mm wrench to remove the brake chamber air line fitting from the modulator valve.

IMPORTANT: The quick connect fittings come with pre-applied dry sealant (Vibra-Seal) which can be reused up to five times. Replace the fitting with a new one if the thread sealant is no longer usable.

10. Use a 23-mm wrench to install the brake chamber air line fitting on the new modulator valve.

11. Use a 1/2-inch socket wrench along with the new bolts, spacers, and washers (supplied in the kit) to install the modulator on the vehicle. Tighten the bolts 11 lbf·ft (15 N·m). See Fig. 10, Fig. 11, Fig. 12, and Fig. 13.

12. Use a 7/8-inch wrench to install the threaded air line that connects the modulator valve to the brake
chamber.

IMPORTANT: The quick connect fittings come with pre-applied dry sealant (Vibra-Seal) which can be reused up to five times. Replace the fitting with a new one if the thread sealant is no longer usable.

13. Use a 7/8-inch wrench to install the quick-connect fitting on the modulator valve.

14. Attach the plastic air line to the modulator.

15. Install the ABS zip tie on the modulator mounting bolt (to prevent chafing).

16. Connect the modulator valve electrical connector.

17. Repeat the procedure for the modulator valve on the other side of the vehicle.

18. Close the hood.

19. Build air pressure to check for leaks and perform six full brake applications in the parking lot to verify proper brake performance.

20. Clean a spot on the base label (Form WAR259), and attach a campaign completion sticker for FL966 (Form WAR260), indicating this work has been completed.

 

FL966C – Front Modulator Valve Replacement

For vehicles belonging to group C, the replacement procedure is the same as groups A and B, but the location of the valves is different. Location of the modulator valve is shown in Fig. 14 and Fig. 15.

 

FL966F – Front Modulator Valve Replacement

For vehicles belonging to group F, the replacement procedure is the same as groups A and B, but the location of the valves is different. Location of the modulator valve is shown in Fig. 16.

 

FL966D – Front Modulator Valve Replacement

For vehicles belonging to group D, the replacement procedure is the same as groups A and B, but the location of the valves is different. Location of the modulator valve is shown in Fig. 17 and Fig. 18.

 

FL966E – Front Modulator Valve Replacement

For vehicles belonging to group E, the replacement procedure is the same as groups A and B, but the location of the valves is different. Location of the modulator valve is shown in Fig. 19.

 

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Chronology :

Starting in or around September 2022, based upon information gleaned from a different population of vehicles (those equipped with ACC), DTNA investigated whether non-ACC-equipped vehicles could have similar brake pull events. Initial indications, testing, and engineering judgment were that they would not. However in late October 2022, DTNA received a first indication from a driver that a vehicle in this population of vehicles suffered a brake pull. This conflicted DTNA’s indication that this population would not be affected by brake pulls, so in late October 2022, DTNA expanded its investigation, including interviewing drivers and running further tests.

On February 6 2023, DTNA received the first corroboration, a test result under controlled conditions, indicating a possibility of a sudden unexpected brake pull during rare conditions within ESC and RSC events, depending on a number of other factors including environment, speed, driving conditions, and level of valve blockage.

Despite the fact that DTNA has no evidence of field events other than the one driver in October 2022 asserting it happened, and despite the fact that the brake pull differential was not determined to the same degree as was reported during an ACC event, on February 6, 2023, out of abundance of caution, DTNA decided to initiate a new voluntary safety recall to campaign all vehicles equipped with painted and unpainted front brake modulator valves, covering the separate population that are not equipped with ACC.

On February 16, 2023, DTNA reviewed records and amended the population.

 


12 Affected Products

Vehicles

MAKE MODEL YEAR
FREIGHTLINER 114SD 2022
FREIGHTLINER CASCADIA 2017-2023
WESTERN STAR 47X 2022-2023
WESTERN STAR 49X 2022-2023

 


33 Associated Documents

Amended Defect Information Report

RMISC-23V073-9716.pdf 636.911KB

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Recall 573 Report – February 15, 2023

RCLRPT-23V073-7704.PDF 216.059KB

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Recall 573 Report – February 16, 2023

RCLRPT-23V073-3461.PDF 216.121KB

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Recall 573 Report – February 16, 2023

RCLRPT-23V073-8549.PDF 216.121KB

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Defect Notice 573 Report

RCLRPT-23V073-7976.PDF 215.804KB

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Amended Defect Information Report

RMISC-23V073-9183.pdf 636.848KB

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Recall Acknowledgement

RCAK-23V073-4061.pdf 690.71KB

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Recall 573 Report – February 16, 2023

RCLRPT-23V073-2524.PDF 216.064KB

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Defect Information Report

RMISC-23V073-1193.pdf 690.09KB

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Recall 573 Report – February 21, 2023

RCLRPT-23V073-1440.PDF 216.21KB

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Amended Defect Information Report

RMISC-23V073-3650.pdf 733.766KB

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Recall 573 Report – February 23, 2023

RCLRPT-23V073-2716.PDF 216.19KB

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Recall 573 Report – March 21, 2023

RCLRPT-23V073-2176.PDF 216.18KB

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Amended Defect Information Report

RMISC-23V073-8838.pdf 735.322KB

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Recall 573 Report – March 21, 2023

RCLRPT-23V073-2705.PDF 216.216KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-8077.pdf 742.396KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-23V073-8123.pdf 187.928KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-1551.pdf 144.694KB

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Updated Chronology – September 25, 2023

RMISC-23V073-3261.pdf 72.823KB

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Recall 573 Report – Amendment 9

RCLRPT-23V073-8588.PDF 215.897KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-3907.pdf 761.832KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-2891.pdf 141.98KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-9213.pdf 752.759KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-0048.pdf 74.723KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-4035.pdf 170.248KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-9102.pdf 85.708KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V073-4019.pdf 193.366KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-8927.pdf 755.467KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-2180.pdf 229.359KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-5825.pdf 225.766KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-5141.pdf 227.424KB

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Recall Quarterly Report #1, 2023-4

RCLQRT-23V073-1804.PDF 211.297KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V073-5814.pdf 227.133KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V073&docType=RCL

 


 

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