Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

Subject: FCCC Chassis Rocker Arms and Intake Gaskets
Models Affected: Specific Freightliner Custom Chassis B2 school
bus chassis (Thomas Built Buses Saf-T-Liner C2) and S2G chassis
manufactured April 3, 2013, through June 28, 2017.

General Information
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Freightliner Custom
Chassis Corporation, is initiating Field Service Campaign SF548AB to modify the vehicles mentioned above.
Certain vehicles were built with rocker arms that may fail prematurely. Premature failure may be detected by
abnormal engine noise and misfire. Certain vehicles may also have faulty intake gaskets which may be detected
by a milky white appearance of the engine oil and on the underside of the engine oil fill cap.
Intake gaskets and rocker arms will be replaced on the corresponding suspect vehicles.
There are approximately 1,531 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 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 SF548AB, 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 SF548
Campaign Number

Kit Number
25-SF548-000

SF548A
25-SF548-001
N/A
SF548B

25-SF548-001
N/A

Part Description
L18 ROCKER ARMS
ROCKER ARM BALLS
ROCKER NUTS
INTAKE GASKETS
WASHERS
BLANK COMPLETION STICKER
INTAKE GASKETS
WASHERS
BLANK COMPLETION STICKER

Table 1

Page 1

Part Number
N/A

N/A
WAR260
N/A
WAR260

Qty. per Kit
16 ea
16 ea
16 ea
2 ea
12 ea
1 ea
2 ea
12 ea
1 ea

Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

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

Procedure

Time Allowed
(hours)

SRT Code

Corrective Action

SF548A
SF548B

Replace the rocker arms and intake gaskets
Replace the intake gaskets

11.6
5.2

996-F003A
996-F003B

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 OWL:
• Claim type is Field Service Campaign.
• In the Campaign field, enter the campaign number and appropriate group (SF548-A or SF548-B).
• In the Primary Failed Part field, enter 25-SF548-000.
• In the Parts section, enter the appropriate kit and/or part number(s) as shown in the Replacement Parts
Table. NOTE: Up to $105.00 in needed shop supplies can be included on your claim without preapproval
(oil, filter, coolant, sealants).
• 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 045-008-052 and the Cause Code is A1 - Campaign.
• This Field Service Campaign will terminate on December 31, 2018. Dealers will be notified of any
changes to the termination date via Important Campaign Information Letter posted on DTNAConnect.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 via Web inquiry at
DTNAConnect.com / WSC, 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

Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

Copy of Notice to Owners
Subject: FCCC Chassis Rocker Arms and Intake Gaskets
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Freightliner Custom
Chassis Corporation, is initiating Field Service Campaign SF548AB to modify specific Freightliner Custom
Chassis B2 school bus chassis (Thomas Built Busses Saf-T-Liner C2) and S2G chassis manufactured
April 3, 2013, through June 28, 2017.
Certain vehicles were built with rocker arms that may fail prematurely. Premature failure may be detected by
abnormal engine noise and misfire. Certain vehicles may also have faulty intake gaskets which may be detected
by a milky white appearance of the engine oil and on the underside of the engine oil fill cap.
Intake gaskets and rocker arms will be replaced on the corresponding suspect vehicles.
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.Daimler-TrucksNorthAmerica.com / Contact Us / Find a Dealer. The campaign will take approximately 6 to
12 hours, depending on the repair, and will be performed at no charge to you.
This Field Service Campaign will terminate on December 31, 2018. 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

Page 3

Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

Work Instructions
Subject: FCCC Chassis Rocker Arms and Intake Gaskets
Models Affected: Specific Freightliner Custom Chassis B2 school
bus chassis (Thomas Built Buses Saf-T-Liner C2) and S2G chassis
manufactured April 3, 2013, through June 28, 2017.

Rocker Arm and Gasket Replacement
1.

Check the base label (Form WAR259) for a completion sticker for SF548 (Form WAR261) 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. On school buses, the base label is usually located over the driver’s window.
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 battery.

WARNING
Do not release propane inside a garage or building. Eliminate all sources of ignition prior to depressurizing a fuel line. Ignition of propane vapors can cause property damage and or serious personal injury.
Fuel line depressurization must be performed outdoors unless the fuel line has already been depressurized outside prior to pulling vehicle into the garage. Always wear gloves and eye protection when opening a propane line that may contain liquid propane. Liquid propane escaping from a fuel line can cause
severe freeze burns much like frostbite.
4.

Shut off the supply of fuel to the engine, both the supply and return valves need to be closed.
4.1

Locate the supply valve. See Fig. 1, Item 1, for Saf-T-Liner C2 School Bus and Fig. 2 for S2G delivery truck.

1. Supply Valve

2. Return Valve

Fig. 1, School Bus Fuel Line Valves

1. Supply Valve
Fig. 2, S2G Delivery Truck, Supply Valve
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Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

4.2

To shut off the supply valve, turn the valve handle clockwise until it reaches its stop (roughly three
and a half turns).

NOTICE
Damage may occur to the fuel tank valve(s) if the valve(s) are overtightened.
4.3

Locate the return valve. See Fig. 3. To shut off the return valve, turn the valve handle clockwise until
it reaches its stop (roughly two and a quarter turns).

WARNING
Do not release propane inside a garage or building. Eliminate all sources of ignition prior to depressurizing a fuel line. Ignition of propane vapors can cause property damage and or serious personal injury.
5.

Drain the fuel lines.
5.1

Slowly loosen the engine supply hose until a white fog is released from the hose.

5.2

Once the white fog dissipates, loosen the line 1/4 turn more to ensure all the propane pressure has
been released from the supply line.

5.3

Slowly loosen the tank return hose until a white fog is released from the return hose.

5.4

Once the white fog dissipates from the return line, loosen the return line 1/4 turn more to ensure all
the propane pressure has been released from the system.

6.

Drain the coolant from the engine.

7.

Remove the two 3/8-inch coolant hoses from the coolant surge tank as well as the P-clamp that attaches
one of the hoses to the upper intake manifold. Move the hoses out of the way.

8.

Disconnect the electrical wiring from the alternator.

9.

Remove the four bolts retaining the alternator to the bracket.

10.

Remove the serpentine belt and alternator.

11.

Disengage the locking device and remove the electrical connector at the torque security module (TSM).
See Fig. 4.

1. Return Valve
Fig. 3, S2 Delivery Truck, Return Valve

Disengage the locking device and remove the
electrical connector.
Fig. 4, Torque Security Module

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Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

12.

Remove the three TSM mounting bolts, then remove the TSM and shield.

13.

Disengage the locking devices and remove the three electronic control module (ECM) connectors at the
ECM. See Fig. 5. Move the harness out of the way.

14.

Remove the wire ties retaining the wire harness to the upper intake and move the harness out of the way.

15.

Remove the three ECM mounting bolts and remove the ECM.

NOTE: Do not drop the ECM or TSM. Store both components in a safe location. The ECM and TSM should not
be exposed to, or immersed in, solvents or cleaners.
16.

Disconnect the P-clamp that attaches the transmission dipstick on the L-shaped bracket, bolted on the upper intake (left-hand side).

17.

Disconnect the electrical connector from the MAP sensor (rear right-hand corner of the upper intake). See
Fig. 6. Gently pry the blue tab away from the connector body to unlock it.

18.

Remove the electrical connector from the throttle body.

19.

Disconnect the electrical connector from the purge valve (right-rear side of the intake).

20.

Press the locking feature on the fitting and remove the post crankcase ventilation (PCV) hose from the
PCV valve on the right-hand rocker cover, and then remove the hose from the rear of the upper intake
manifold.

21.

Disengage the locking feature from the mass airflow sensor connector and remove the connector from the
mass airflow sensor.

Disengage the locking devices and remove the
three ECM connectors.
Fig. 5, Electronic Control Module

1.
2.
3.
4.

MAP Sensor
Purge Hose
Post Crankcase Ventilation Hose
Purge Solenoid
Fig. 6, Upper Intake Manifold Components

Page 6

Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB
22.

Press the locking feature on the PCV hose connected to the rear side of the air intake tube and remove
the PCV hose from the air intake tube.

23.

Remove the air intake tube from the throttle body and air cleaner.

NOTE: Remove the air filter housing bracket (along with the filter housing and hose) from the firewall by removing the four T40 torx bolts.
24.

Remove the eight upper intake manifold securing nuts and four bolts along with any brackets secured by
the fasteners.

25.

If necessary, disconnect the metal tubing from the top of the air compressor and move it out of the way.

26.

Remove the purge hose from the upper intake manifold. See Fig. 6.

27.

Remove the purge solenoid and bracket.

28.

Remove the top radiator hose at the thermostat housing.

29.

Remove the thermostat housing and thermostats.

NOTICE
Never pry the upper intake manifold to remove it. The use of prying tools may cause damage to the
sealing surfaces of the lower and upper manifold and studs. If the O-rings are not damaged they may be
used again.
30.

Remove the upper intake manifold from the lower intake manifold by lifting straight up over the studs.

IMPORTANT: Cover all the openings in the lower intake manifold to prevent foreign objects from entering the
engine.
31.

Reposition the spring clamp on the 1-inch bypass hose by moving it up and off the tube in the water
pump. When the front of the intake is pried upward and removed, the bypass hose should remain on the
lower intake.

32.

Move the air compressor hose clamp out of the way and remove the ½-inch coolant hose from the rear of
the air compressor.

33.

Remove the wire ties retaining the engine harness to the intake near the thermostat housing and on the
top-left side at the coolant crossover.

34.

Remove the electrical connector from the fuel bypass solenoid at the rear of the intake manifold.

WARNING
Liquid propane can cause serious burns should it contact the skin or eyes. When handling propane, always wear protective gloves and eye protection to prevent contact.
Propane is extremely flammable, and can ignite if an ignition source is present, causing burns and
other serious injuries. Keep sparks and flames away from propane, as well as the fuel lines. Keep the
work area well ventilated.

Page 7

Daimler Trucks
North America LLC

Field Service Campaign

December 2017
SF548AB

CAUTION
Use caution when removing the fuel lines. Residual liquid propane may be present in the lines and under pressure. Carefully loosen the connections to allow any reside to escape before removing the fuel
lines.
35.

Slightly open the fuel supply and return lines to relieve residual pressure. The supply line is on the driverside and is the larger of the two lines that connect to the rear of the intake manifold.