FL938 – Steering Gear Incorrectly Assembled – 2021-2022 Freightliner (FCCC) MT45, 2022-2023 Western Star 4900 & Freightliner Cascadia

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June 8, 2022 NHTSA CAMPAIGN NUMBER: 22V405000

Steering Gear Incorrectly Assembled

A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V405

Manufacturer Daimler Trucks North America, LLC

Components STEERING

Potential Number of Units Affected 6,492

 

Summary

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2022 Freightliner (FCCC) MT45, 2022-2023 Western Star 4900 and Freightliner Cascadia vehicles. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.

 

Remedy

Dealers will inspect and replace the steering gears, as necessary, free of charge. Owner notification letters were mailed December 28,2022. Owners may contact DTNA’s customer service at 1-800-547-0712. DTNA’s number for this recall is FL-938.

 

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

 


December 2022
FL938A-E
NHTSA #22V-405
Transport Canada #2022-300

Subject: Steering Gears

Models Affected: Specific model years 2022-2023 Freightliner Cascadia and Freightliner Custom Chassis MT45, and MT45G vehicles, manufactured June 9, 2021, through May 23, 2022, and equipped with an RH Sheppard steering gear.

General Information

Daimler Truck North America LLC (DTNA), on behalf of its Freightliner Trucks Division, and wholly owned subsidiary, Freightliner Custom Chassis Corporation, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.

On certain vehicles, an insufficient number of recirculating balls in the steering gear may cause the gear’s internal parts to fracture, resulting in loss of steering, which could increase the risk of a crash.

The steering gear will be inspected and replaced as needed.

There are approximately 6,000 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 FL938A-E, a list of the customers and vehicle identification numbers will be available on DTNAPortal. Please refer to this list when ordering parts for this recall.

Table 1 – Replacement Parts for FL938A-E

Campaign Number Part Description Part Number Qty.
FL938A-C STEERING GEAR RHS MD83PB3Y 1 ea
FL938D-E STEERING GEAR RHS HD94PBE3Y 1 ea
FL938A-E BLANK COMPLETION STICKER WAR260 1 ea

Table 1

 

Work Instructions

Subject: Steering Gears

Models Affected: Specific model years 2022-2023 Freightliner Cascadia and Freightliner Custom Chassis MT45, and MT45G vehicles, manufactured June 9, 2021, through May 23, 2022, and equipped with an RH Sheppard steering gear.

 

Steering Gear Inspection and Classification

1. Check the base label (Form WAR259) for a completion sticker for FL938 (Form WAR260) indicating this work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) be-low 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. Locate the steering gear on the front left frame rail of the vehicle.

 

4. Locate the serial number on the steering gear. See Fig. 1.

 

5. To determine if the steering gear needs replacement, go to https://qa-recall.rhsheppard.com/USA/en/USD

 

6. Select the ‘Select Vehicle Make’ option. From the dropdown menu, select ‘FREIGHTLINER, DAIMLER TRUCK.’ See Fig. 2.

 

7. Enter the steering gear serial number, noted in step 4, in the designated field. Select ‘Search.’ See Fig. 2.

 

8. Check for the result received.

Good, as shown in Fig. 3 → No further action is required. Clean a spot on the base label (Form WAR259) and attach a campaign completion sticker for FL938 (Form WAR260), indicating this work has been completed.

Suspect, as shown in Fig. 4 → Replace the steering gear. Go to Steering Gear Replacement procedure.

 

Steering Gear Replacement

1. What is the make of the vehicle?

Freightliner → For instructions to replace the steering gear, see Section 46.04, Subject 100 of the New Cascadia workshop manual. Then go to step 33.

FCCC → Follow the steps 2 through 33 to replace the steering gear.

 

NOTE: Ensure the wheels are facing straight ahead throughout the steering gear replacement procedure.

 

2. Remove the cotter pin from the castle nut at the steering arm-to-draglink connection. See Fig. 5.

 

3. Use a 1-1/8 inch socket to remove the castle nut. Retain the castle nut for installation in the later step. Remove the draglink from the pitman arm.

 

4. At the pitman arm-to-steering gear connection, use a punch to bend the retaining tabs out of the pitman arm retainer. See Fig. 6.

 

IMPORTANT: To avoid difficulty in removing the pitman arm, ensure to lubricate the face of the retainer.

 

5. Lubricate the face of the retainer with a clean chassis lube.

 

6. Disconnect the pitman arm from the steering gear.

6.1 Slide the pitman arm puller over the pitman arm. Align the hole in the puller with the Allen socket in the retainer.

6.2 Insert the Allen drive socket through the puller and into the retainer socket. Use an impact wrench to back off the retainer. The retainer will act as a jackscrew to disconnect the pitman arm from the steering gear.

 

7. Use a 5/8-inch wrench and a 11/16-inch socket to remove the pinch bolt that attach the steering linkage to the top of the steering gear. Discard the fasteners. See Fig. 7.

 

8. Remove the steering linkage from the gear by sliding the shaft upwards, away from the steering gear.

 

9. Use a 7/8-inch wrench to loosen and remove the hydraulic lines from the fittings on the rearward-facing side of the steering gear. See Fig. 8

 

10. Use a 7/8-inch wrench to remove the fittings from the steering gear. Retain the fittings for installing on the replacement gear.

 

11. Use a 1-1/8 inch socket and wrench to remove the three bolts and washers that attach the steering gear to the rail. Discard the fasteners. See Fig. 9.

 

12. Remove the steering gear.

NOTICE

The head side of bolts needs to be inboard, inside the rail flange.

13. Install the washer (23-09114-004) on the new bolt (23-11757-350), then install the bolts into the three holes
in the rail.

 

14. Install the new steering gear (RHS MD83PB3Y) on the bolts in the rail. Install the washer (23-09114-004) first, and then install the nut (23-13833-112). Tighten the fasteners hand tight.

 

15. Use a 1-1/8 inch socket and wrench to tighten the fasteners that attach the steering gear to the rail. Tighten the fasteners 221 lbf·ft (300 N·m).

 

16. Install the hydraulic hose fittings in the gear, oriented as shown in Fig. 8. Tighten the hose fittings 45 lbf·ft (61 N·m).

 

17. Install the hose on the fittings, and tighten them hand tight.

 

18. While holding the small part of the fittings using a 3/4-inch wrench, use a 7/8-inch wrench to tighten the hose fittings. Tighten the hose fittings 45 lbf·ft (61 N·m).

 

19. Make sure the bolt hole in the steering linkage, and the groove on the steering gear input shaft align properly.

Install the steering linkage on top of the gear. See Fig. 10.

 

20. Install the new bolt (14-18773-001) and the nut (14-18774-000) on the steering shaft. Tighten the nut 43 lbf·ft (58 N·m).

 

21. Align the timing marks on the pitman arm with the timing marks on the sector shaft, then install the pitman arm on the sector shaft. The timing marks will appear as shown in Fig. 11 and Fig. 12.

 

22. Install the pitman arm retainer on the sector shaft. Make sure to align the tabs in the notches of the pitman arm.

 

23. Coat the threads of the retainer with an antiseize compound. A coating of antiseize should be applied to both sides of the friction washer if a new retainer is being used.

 

24. Tighten the retainer 225 lbf·ft (305 N·m).

NOTE: Do not back off the torque value to align the tabs. If the pitman arm is not tightened to the specified torque, it can come loose.

 

25. Continue tightening the retainer past the specified value until two of the notches in the retainer align with the tabs of the washer.

 

26. Use a punch and hammer to bed the retaining tabs of the washer into the notches on the retainer. Apply the torque seal.

 

27. Install the draglink on the pitman arm, then install the castle nut removed in step 2. Tighten the castle nut hand tight.

 

28. Tighten the castle nut 70 lbf·ft (95 N·m).

 

29. If the cotter pin hole is not accessible, advance the castle nut to the nearest slot, and install the cotter pin. Bend the split side of cotter pin around the nut as shown in Fig. 5.

 

30. Verify no leaks are present, and fill the power steering reservoir with fluid (48-02182-001).

 

31. Turn the steering wheel to extremities in clockwise and counter clockwise directions to check the clearance and function of steering components.

 

32. Road test the vehicle to ensure proper steering functionality.

 

33. Clean a spot on the base label (Form WAR259) and attach a campaign completion sticker for FL938 (Form WAR260), indicating this work has been completed.

 

 

 


Chronology :

DTNA’s supplier Bendix, acting through subsidiary R.H. Sheppard Co., Inc. states per NHTSA filing 22E-047:

2/8/22-Sheppard warranty lab receives a gear built 8/20/2021 with failed worm-shaft.

2/9/22 – warranty lab inspection/disassembly indicates fracture of the worm-shaft and less than the required number of recirculating balls

2/10/22-plant stops production. Additional inspections and process verifications put in place. Clean point is established. Material on hand is inspected and confirmed defect free. Production resumes.

(2/10/22 – 5/13/22): review of all warranty from 2015-present indicated no similar failure ever received. engineering tests are performed to understand and to reproduce failure mode.

3/10/2022 – Sheppard contacted vehicle driver for description of event and confirmed no accident or injury, low speed and while backing up.

4/12/22 – Sheppard receives a second gear at incoming shipping facility

5/5/22- Sheppard warranty lab receives/inspects/disassembles the second gear built on 6/26/21 with failed worm-shaft and
less than the required number of recirculating balls

5/6/22- The Product Integrity Committee meets for update on the product investigation.

5/13/22 – The Product Integrity Committee meets and recommends submission of a defect report 573.”

Bendix notified DTNA on May 25, 2022 of a possible defect. DTNA investigated the matter and promptly declared a recall.

Meanwhile, thru early June of 2022, Bendix continued to refine the serial numbers of the suspect parts and around mid-June, provided DTNA an updated list of suspect component serial numbers. DTNA immediately began the process of matching vehicle serial numbers to the suspect steering gear serial numbers. After an exhaustive review of available data, DTNA was able to refine and match the list from Bendix to the population as of this filing. There are no known deaths or injuries related to issue to the best of DTNA’s knowledge. (Full description provided in the report)

 


22E047 – Steering Gear Assembled Incorrectly – Sheppard

 

22E047 – Steering Gear Assembled Incorrectly – Sheppard

 


6 Affected Products

Vehicles

MAKE MODEL YEAR
FCCC MT45 2021-2022
FREIGHTLINER CASCADIA 2022-2023
WESTERN STAR 4900 2022-2023

 


16 Associated Documents

Recall Acknowledgement

RCAK-22V405-3163.pdf 645.695KB

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Defect Notice 573 Report

RCLRPT-22V405-3906.PDF 215.796KB

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Defect Information Report

RMISC-22V405-2174.pdf 833KB

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Recall 573 Report – June 28, 2022

RCLRPT-22V405-9922.PDF 215.228KB

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Amended Defect Information Report

RMISC-22V405-4306.pdf 831.491KB

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Recall 573 Report – July 11, 2022

RCLRPT-22V405-6984.PDF 215.253KB

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Amended Defect Information Report

RMISC-22V405-3623.pdf 831.747KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V405-8102.pdf 398.865KB

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V405-1032.pdf 187.034KB

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Amended Defect Information Report

RMISC-22V405-0277.pdf 832.172KB

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Recall 573 Report – October 24, 2022

RCLRPT-22V405-6489.PDF 214.963KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V405-9130.pdf 649.975KB

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Body Builder-Owner Notice

RMISC-22V405-1374.pdf 104.636KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V405-1887.pdf 435.852KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V405-7579.PDF 211.144KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V405-4886.PDF 211.244KB

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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=22V405&docType=RCL

 


 

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