Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

SB-10057451-1695
Subject: FCCC MT45G/55G Fuel Pump and Starter Relays
Models Affected: Specific Freightliner Custom Chassis
MT45G/55G chassis manufactured February 15, 2010, through
March 31, 2014, with certain starter or fuel pump relays.

General Information
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Freightliner Custom Chassis
Corporation, is initiating Field Service Campaign SF502A to modify the vehicles mentioned above.
Certain fuel pump and starter relays are experiencing less than desired life.
To resolve the problem, larger, more robust relays will be installed.
There are approximately 11,399 vehicles involved.
Additional Repairs
Dealers must complete all outstanding 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.
Please contact Warranty Campaigns for consideration of additional charges prior to performing the repair.

Work Instructions
Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a completion
sticker (Form WAR261).

Replacement Parts
Replacement parts are now available and can be obtained by ordering the kit number listed below from your facing
Parts Distribution Center.
If our records show your dealership has ordered any vehicle(s) involved in campaign SF502A, a list of the customers
and vehicle identification numbers will be available on AccessFreightliner.com. Please refer to this list when ordering
parts for this campaign.
Table 1 - Replacement Parts for SF502
Campaign Number

SF502A

Kit Number

25-SF502-000

Part Description

Part Number

Qty. per Kit

PLUG-4CAV,HDSCS,AI 2-1418390-1

23-13149-404

1 ea

SEAL-CAV PLUG,1.5S,2.5S,JPTAS

AI 828922 1

6 ea

CLAMP-CABLE TIE,1-3/4X8

23-09796-309

4 ea

NUT-HEX,FLG,1/4-20,LOCK,ZN/AL

23-13861-104

1 ea

HARN-RLY JMPR

A06-92991-000

1 ea

RELAY

66-01377-000

1 ea

Table 1

Page 1

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

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 2 - Labor Allowance
Campaign
Number
SF502A

Procedure

Time Allowed
(hours)

SRT Code

Corrective Action

Inspect Relays

0.1

996-0937A

06-Inspect

Inspect Relays, Replace One Relay

0.4

996-0937B

12-Repair Recall/Campaign

Inspect Relays, Replace Two Relays

0.6

996-0937C

12-Repair Recall/Campaign

Table 2

IMPORTANT: When the campaign has been completed, locate the base completion label in the appropriate
location on the vehicle, and attach the gray completion sticker provided in the field service kit (Form WAR261). 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 field service kit is not required or there is no completion
sticker in the kit, write the campaign 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 QuickClaim or OWL:
• Claim type is Field Service Campaign.
• In the Campaign field, enter the campaign number and appropriate group (SF502A).
• In the Primary Failed Part field, enter 25-SF502-000.
• In the Parts section, enter the appropriate kit number(s) as shown in the Replacement Parts Table.
• In the Labor section, 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 037-001-003 and the Cause Code is A1 - Campaign.
This Field Service Campaign will terminate on March 31, 2016. Dealers will be notified of any changes to the
termination date via Important Campaign Information Letter posted on AccessFreightliner.com.
IMPORTANT: OWL must be viewed prior to beginning work to ensure the vehicle is involved and the campaign
has not previously been completed. Also, check for a completion sticker before beginning work.
All claims must be submitted within 30 days of the repair and within 30 days of the termination date of the
campaign. U.S. and Canadian Dealers: All excess inventory to be returned to the PDC following the conclusion of
the campaign must be returned in resaleable condition to the Memphis PDC within 90 days from the termination
date. Please submit a PAR to request return to the Memphis PDC. (Canadian dealers should return the kits to
their facing PDC.) Export Distributors: Excess inventory is not returnable.
.
For questions, U.S. and Canadian dealers, contact the Warranty Campaigns Department from 7:00 a.m. to 4:00
p.m. Pacific Time, Monday through Friday, via Web inquiry at AccessFreightliner.com / Support / My Tickets and
Submit an Inquiry, or the Customer Assistance Center at (800) 385-4357, after normal business hours, if you have
any questions or need additional information. Export distributors submit a Web inquiry or contact your International
Service Manager.

Page 2

Field Service Campaign

Daimler Trucks
North America LLC
March 2015
SF502A

Copy of Notice to Owners
Subject: FCCC MT45G/55G Fuel Pump and Starter Relays
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Freightliner Custom Chassis
Corporation, is initiating Field Service Campaign SF502A to modify specific Freightliner Custom Chassis
MT45G/55G chassis manufactured February 15, 2010, through March 31, 2014, with certain starter or fuel pump
relays.
Certain fuel pump and starter relays are experiencing less than desired life.
To resolve the problem, larger, more robust relays will be installed.
Please contact an authorized Daimler Trucks North America dealer to arrange to have the campaign performed and
to ensure that parts are available at the dealership. To locate an authorized dealer, search online at www.DaimlerTrucksNorthAmerica.com / Contact Us / Find a Dealer. The campaign will take approximately one hour and will
be performed at no charge to you.
This Field Service Campaign will terminate on March 31, 2016 . Please make sure the campaign is completed
prior to this date. Work completed after this date will be done at the customer’s expense.
As stated in the terms of your express limited warranty, Daimler Trucks North America LLC will not pay for any
damage caused by failure to properly maintain your vehicle. Daimler Trucks North America LLC considers the
work necessary under this campaign to be proper maintenance and will, therefore, not pay for any damage to your
vehicle caused by your failure to have the repairs that are the subject of this campaign performed in a reasonable
time.
Contact the Warranty Campaigns Department at (800) 547-0712, from 7:00 a.m. to 4:00 p.m. Pacific Time, Monday
through Friday, e-mail address [email protected], or the Customer Assistance Center at
(800) 385-4357, after normal business hours, if you have any questions or need additional information.

WARRANTY CAMPAIGNS DEPARTMENT
Enclosure

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

Work Instructions
Subject: FCCC MT45G/55G Fuel Pump and Starter Relays
Models Affected: Specific Freightliner Custom Chassis
MT45G/55G chassis manufactured February 15, 2010, through
March 31, 2014, with certain starter or fuel pump relays.

Starter and Fuel Pump Relay Inspection
1. Inspect the base label (Form WAR259) for a campaign completion sticker for SF502 (Form WAR261), indicating
that the work has been completed. If no sticker is present, check for new relay(s). If there is a completion
sticker or new relay(s), no work is needed. If no sticker or new relay(s) is present, 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 power distribution module (PDM) shown in Fig. 1 and remove it from the mounting bracket. Remove
the PDM cover. See Fig. 2.
4. Inspect to see if the starter and fuel pump relays have been replaced.
• if yes, place the PDM cover on the PDM, install the PDM to the mounting bracket, then go to the last
step in these work instructions.
• If the starter relay needs replacing, proceed to Starter Relay Replacement on page 5.
• If the fuel pump relay needs replacing, proceed to Fuel Pump Relay Replacement on page 8.

1

08/28/2014

A

A. Fuel Pump Relay

B
B. Starter Relay

Fig. 2, Removing the Relay

08/28/2014

f470645

1. Power Distribution Module
Fig. 1, Power Distribution Module Location

Page 4

f470646

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

Starter Relay Replacement
IMPORTANT: The recommended pin removal tool is manufactured by Tyco and shown in Fig. 3. Alternative generic
tools are shown in Fig. 4 and Fig. 5.
If an alternative extraction tool is used, position one tool on each side of the terminal to disengage the terminal
lock, then gently pull on the circuit to remove it from the cavity. See Fig. 6. If excessive force is required, the locks
are not released. Reposition the tools and try again.

09/23/2014

f470657

Fig. 4, Delphi Extraction Tool

09/23/2014

f470656

Fig. 3, Tyco Pin Removal Tool

09/23/2014

f470658

Fig. 5, Generic Extraction Tool

1. Using the pin removal tool, carefully remove the four wires from the PDM, as shown in Fig. 7. Install the wires
in the new connector, shown in Fig. 8, in the following order.
1.1

Remove circuit GND from cavity D10 and place it in new connector pin 1.

1.2

Remove circuit 15G from cavity E9 and place it in new connector cavity 2.

1.3

Remove circuit 15B from cavity D9 and place it in new connector cavity 3.

1.4

Remove circuit 15C from cavity E10 and place it in new connector cavity 4.

1.5

Make certain each circuit is properly seated in the new connector.

Page 5

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

2
3

1
4

08/29/2014

1.
2.
3.
4.

Cavity
Cavity
Cavity
Cavity

f470653

E10 (circuit 15C)
E9 (circuit 15G)
D9 (circuit 15B)
D10 (GND)

Fig. 7, Old Starter Relay Wire Cavity Locations

09/23/2014

f470659

3

2

1

4

Fig. 6, Positioning the Alternative Extraction Tools
08/29/2014

1. Cavity 1 (GND)
2. Cavity 2 (circuit 15G)

f470648

3. Cavity 3 (15B)
4. Cavity 4 (15C)

Fig. 8, New Connector (wire insertion side shown)

Page 6

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

2. Insert plugs in the empty PDM pin cavities. See Fig. 9.
3. Connect the new relay to the jumper harness. See Fig. 10.

08/29/2014

f470654
08/28/2014

Fig. 9, Inserting Plugs

f470649

Fig. 10, Jumper Harness

4. Route the jumper harness along the main bundle and use tie bands to secure it. See Fig. 11
5. Using the slot in the connector, attach the connector to the bundle as shown in Fig. 12

2

1

08/29/2014

f470650

1. Tie Bands

2. Jumper Harness

08/29/2014

f470651

Fig. 12, Attaching the Connector

Fig. 11, Routing the Jumper Harness

Page 7

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

6. Using the 1/4-inch flange nut, mount the relay on the protruding bolt of the PDM mounting bracket as shown
Fig. 13. If another relay is already mounted, mount the starter relay as shown in Fig. 14.

1
1

2

08/29/2014

f470652

1. Mounting Bolt

2. Relay

Fig. 13, Mounting the Relay on the PDM Bolt

2

08/29/2014

1. Relay 1

f470655

2. Relay 2

Fig. 14, Mounting the Relay, Alternate Method

7. Replace the PDM cover on the PDM, then install the PDM to the mounting bracket.
8. If the fuel pump relay needs to be replaced, go to "Fuel Pump Relay Replacement" (below). If not, proceed
to the next step.
9. Clean a spot on the base label (Form WAR259) and attach a completion sticker (Form WAR261) to indicate
the work has been completed.

Fuel Pump Relay Replacement
IMPORTANT: The recommended pin removal tool is manufactured by Tyco and shown in Fig. 3. Alternative generic
tools are shown in Fig. 4 and Fig. 5. See page 5.
If an alternative extraction tool is used, position one tool on each side of the terminal to disengage the terminal
lock, then gently pull on the circuit to remove it from the cavity. See Fig. 6. on page 6. If excessive force is required,
the locks are not released. Reposition the tools and try again.
1. Using the pin removal tool, carefully remove the four wires from the PDM, as shown in Fig. 15. Install the
wires in the new connector, shown in Fig. 16, in the following order.
1.1

Remove circuit 246 from cavity A4 and place it in new connector cavity 1.

1.2

Remove circuit GND from cavity B3 and place it in new connector cavity 2.

1.3

Remove circuit 246B from cavity B4 and place it in new connector cavity 4.

1.4

Remove circuit 246A from cavity A3 and place it in new connector cavity 3.

1.5

Make certain each circuit is properly seated in the new connector.

Page 8

Daimler Trucks
North America LLC

Field Service Campaign
March 2015
SF502A

1
3

2

1

4

2

3
08/29/2014

1. Cavity 1 (246)
2. Cavity 2 (GND)

1.
2.
3.
4.

Cavity
Cavity
Cavity
Cavity

3. Cavity 3 (246A)
4. Cavity 4 (246B)

Fig. 16, New Connector (wire insertion side
shown)

4

08/28/2014

f470648

f470647

B3
A3
A4
B4

(GND)
(circuit 246A)
(circuit 246)
(circuit 246B)

Fig. 15, Old Fuel Pump Wire Cavity Locations

2. Insert plugs in the empty PDM pin cavities. See Fig. 9 on page 7 for an example.
3. Connect the new relay to the jumper harness. See Fig. 10 on page 7.
4. Route the jumper harness along the main bundle and use tie bands to secure it. See Fig. 11 on page 7.
5. Using the slot in the connector, attach the connector to the bundle as shown in Fig. 12 on page 7.
6. Using the 1/4-inch flange nut, mount the relay on the protruding bolt of the PDM mounting bracket as shown
in Fig. 13 on page 8. If another relay is already mounted, mount the starter relay as shown in Fig. 14 on page
8.
7. Replace the PDM cover on the PDM, then install the PDM to the mounting bracket.
8. Clean a spot on the base label (Form WAR259) and attach a completion sticker (Form WAR261) to indicate
the work has been completed.

Page 9