May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

1

4

2

6
7

5

3

02/19/2019

1.
2.
3.
4.

f546904

GNDE Frontwall Pass-Through Stud
GNDP Non-Isolated Stud
Cab Ground Harnesses (mod 28G)
GNDE Ground Terminals (harnesses not shown for
clarity)

5. GNDE to Battery
6. Cab Skin Ground Cable
7. Chassis Ground Harness to frame rail (mod 2YU)

Fig. 5, MGJB and Frontwall Grounds

02/18/2019

f546945

Fig. 6, GNDP Cab Skin Stud
Page 8

02/18/2019

f546944

Fig. 7, GNDE Engine-Side Pass-Through Stud

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE
NOTE: There should always be FOUR ring eyes attached to the GNDP non-isolated stud. The non-isolated
stud itself is NOT a return path to ground through the bracket and relies on the grounding cable returning to the frame for ground; confirm the 2YU GNDP cable is connected from the stud to the frame rail GNDP
stud (See Fig. 2). The GNDP cab skin cable is oversized, and larger than the return to frame cable.
12. Inspect the GNDP non-isolated stud, located on the lower aft portion of the MGJB bracket. Verify that the
GNDP non-isolated stud is clean, configured properly, and torqued correctly. Disassemble and inspect the
stud for overspray on the flat surfaces, and in between the ring eyes. Verify there are exactly four (4)
circuits on ring eye terminals that attach to the GNDP non-isolated stud on every vehicle. If more or less are
found on this stud, combine this inspection step with the next one for GNDE MGJB, separate and group the
cables until four GNDP connections are confirmed. Fan these GNDP ring eyes properly on the non-isolated
stud and then torque the stud to 16 lbf·ft (21 N·m). Repaint the connection as necessary.
NOTE: No particular location or order is needed for the GNDE terminals, other than ensuring that only GNDE
terminals are located on the MGJB studs.
13. Inspect the GNDE MGJB. Verify that the GNDE Main Ground Junction Block (MGJB) is clean, configured
properly, and torqued correctly. Disassemble and inspect the studs for overspray on the flat surfaces, and in
between the ring eyes, then fan the ring eyes properly and torque the studs 16 lbf·ft (21 N·m). Repaint the
connection as necessary.
14. Inspect the ASAM (advanced signal detect and actuation module) power and ground connections. Check
the torque at the ASAM power and ground connections. Torque them 9 lbf·ft (12 N·m).
NOTE: The driver’s side HVAC floor duct and the main dash harness clipping tie strap may need to be removed
for improved access to the cab side GNDE pass-through.
15. Inspect the GNDE pass-through stud on the cab side of the frontwall. See Fig. 8 and Fig. 9. Wiggle the
cable to check for movement, and service if loose. Torque the stud 7 lbf·ft (9.5 N·m).

2

1

3

11/13/2018

1. GNDE Pass-Through Stud

f546902

2. ASAM
Fig. 8, Ground Locations Inside the Cab

Page 9

3. ASAM Ground

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

02/18/2019

f546943

Fig. 9, Cab Side GNDE Pass-Through Stud

16. Replace the steering wheel clockspring. Refer to Section 46.01.140 in the New Cascadia Workshop
Manual for instructions.

DANGER
The components and chemicals used in the airbag system are hazardous. The system contains components that use combustible chemicals; care must be taken when replacing or handling system components. Damaged or deployed airbag systems should be inspected for leaking propellant chemicals before any attempt is made to remove, replace, or handle the components. If a leak is found, contact
Joyson Safety System at 586-709-6308 (Dominic Ledford) or 586-530-4762 (Dave Gunther) for handling
instructions.
The surface of the deployed airbag may contain small amounts of sodium hydroxide (which is a byproduct of the gas generant combustion) and metallic sodium. Sodium hydroxide may be irritating to
the skin and eyes. Always wear rubber gloves and safety glasses when handling a deployed airbag. Immediately wash your hands and exposed skin areas with water and a mild soap. Flush your eyes immediately if exposed to sodium hydroxide.
Consider undeployed airbags to be dangerous and capable of deploying at any time. Before performing
any work on these systems, review all service literature and comply with the following warnings and
precautions. Unintentional or improper deployment of the airbag system can result in injury or death.
• Carry undeployed airbags with the bag and the trim cover pointed away from your body.
Page 10

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE
• Place undeployed airbags face up on a surface in an enclosed area.
• Do not place objects near or on top of an undeployed airbag.
• Store undeployed and undamaged airbag modules in a cool, dry, enclosed area.
• Keep all liquids, acids, halogens, heavy metals, and heavy salts away from the airbag system. Do not
allow system chemicals to contact other liquids, combustibles, and flammable materials. Doing so could
cause chemical burns or personal injury.
• Do not attempt to disassemble the airbag inflator unit or breach the integrity of the sealed metallic inflator
case.
• Do not cut, drill, braze, solder, weld, probe, or strike any part of the airbag system.
• Do not expose the airbag module to electricity. Never probe a circuit on the airbag side of a connector
unless the harness or airbag is disconnected between the test point and the airbag.
• Do not attempt to adapt, reuse, or install an airbag system in any vehicle other than the specific vehicle
for which it is designed.
• Do not cut wires or tamper with the connector between the vehicle wiring harness and the airbag module
unless the troubleshooting diagnostics specifically direct you to do so. Cutting or removing the connector
from the system will disable the safety shunt and could cause unintentional deployment.
• Allow deployed airbag systems to cool after deployment.
• Airbag systems should be deployed in an open area or outdoors to prevent accidental fires.
• Wear rubber gloves and safety glasses when handling a deployed airbag.
• Keep all heavy objects in the cab secured.
• Store, transport, dispose of, and recycle airbag system components in accordance with all applicable federal, state, and local regulations.
16.1 Remove the fasteners that attach the airbag to the steering wheel.
IMPORTANT: Airbags are designated as a Class 9 Hazardous Material. Airbags must be stored per EPA
guidelines, in quantities up to 250 airbags and for up to 180 days. Reference EPA 40 CFR parts 260, 261,
and 262, and EPA 49 CFR 173.166.
16.2 Remove the airbag, and place it into a storage container pending shipping instructions from DTNA
Warranty. Use the following guidelines when storing the airbags (see also Removed Air Bag Consolidation addendum at the end of the bulletin):
• Store the airbags inside steel drums with a wall and lid thickness no less than 20 gauge. The
lid must be securely affixed with a lever-locking or bolted-ring assembly. The lid drum must
provide ventilation. Ventilation can be achieved by removing the threaded bung fitting and covering the opening with tape. See Fig. 10.
• The drum can be filled with any combination of safety devices to a capacity not greater than
fifty (50) percent of the drum’s total volume. This includes any packaging or cushioning used
to wrap the airbags.
• Dealers expecting a high volume of airbags should use multiple storage drums.
• Dealers will be provided shipping instructions and freight cost reimbursement procedures with
the Final recall or within 180 days, whichever comes first.
• Dealers with questions regarding airbag storage instructions should submit a WSC Ticket.
16.3 Disconnect the clockspring connector from the right hand (RH) switch pod. See Fig. 11.
Page 11

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

1

03/13/2019

f602711

1. Threaded Bung Fitting
Fig. 10, Steel Drum with Bolted Ring Assembly

1.
2.
3.
4.
5.

Steering Wheel Cover Module
Steering Wheel
Clockspring Connectors
Clockspring
Steering Column

Fig. 11, Steering Wheel Cover Module, Steering column
and Clockspring

16.4 Use a 10 mm hex driver to remove the steering wheel bolt. Retain the bolt.
16.5 Remove the steering wheel.
16.6 Remove the clockspring capscrews.
16.7 Remove the clockspring.
16.8 Install the new clockspring and connect it to the dash wiring.
16.9 Tighten the clockspring capscrews to 10 lbf·in (113 N·cm) +/- 1 lbf·in (11 N·cm).
16.10 Thread the switch and airbag connectors through the hole to the right of the steering wheel, and set
the steering wheel on the steering column.
16.11 Make sure that the steering wheel is oriented as straight as possible.
16.12 Apply Loctite® 242 to the steering wheel bolt, then install the bolt and tighten 52 to 66 lbf·ft
(70 to 90 N·m).
16.13 Install the new non-airbag steering wheel cover assembly.
17. Disconnect the airbag ECU.
17.1 Locate the airbag ECU, located beneath the driver’s-side seat.
17.2 Raise the seat to the highest position.
17.3 Remove the B-pillar trim to access the connectors on the airbag ECU.
17.4 Unplug all connectors from the airbag ECU pigtail to the B-pillar harness.
17.5 If the seat is equipped with a lower seat shroud, remove the fasteners and lift the shroud to access
the airbag sensor module.
Page 12

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE
17.6 Disconnect the sensor harness from the cab harness. The connectors are located behind the base of
the B-pillar cover. Pull the wiring from under the floor mat if needed.
17.7 Wrap the connectors with electrical tape, coil the harness, and place the harness into a small plastic
bag. Tape the bag shut to protect the harness from moisture or debris, then secure the plastic bag to
the airbag sensor. See Fig. 12.
17.8 Place the bag behind the seat, and verify that it does not interfere with seat belt retractor operation or
the seat suspension mechanism. See Fig. 12.

02/18/2019

f546940

Fig. 12, Harness Secured Behind the Seat

NOTE: The floor harness connectors to the airbag ECU should be kept behind the B-pillar trim to protect
them.
17.9 Install the B-pillar trim.
18. If the vehicle is equipped with a Rolltek ECU, continue with the next step. If the vehicle is not equipped with
a Rolltek ECU, go to step 20.
19. Disconnect the Rolltek module.
19.1 Remove the access panel from the back of the RollTek module.
19.2 Unplug the yellow 2-pin connector.
19.3 Insert terminating resistor A66-17222-000 into the Rolltek connector, as shown on page 3 of D6616484-000.
Page 13

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE
19.4 Remove the B-pillar lower trim and stow the yellow two-pin connector in the B-pillar cavity, as shown
on page 2 of D66-16484-000.
19.5 Install the B-pillar lower trim.
19.6 Install the plastic cover harness connection cover plate on the RollTek ECU.
20. Connect the batteries. If the vehicle is not equipped with a RollTek ECU, continue with the next step. If the
vehicle is equipped with a RollTek ECU, go to step 22.
21. Two parameters must be changed in order to complete the temporary removal of the airbag. Connect the
vehicle to DiagnosticLink and click on the "Parameter" panel. Allow for the parameters to be read completely by DiagnosticLink, as indicated by the status bar at bottom of page.
NOTE: If there are any pending downloads, remove them before connecting to the server.
21.1 Go to Program Device. There should be an upload pending. Click "Connect to Server" to upload the
vehicle parameters to the server.
21.2 Click "Add." Make sure the correct VIN and hardware is populated in the pop-up window, then click
"OK" and "Connect to Server."
21.3 Use the "Parameters" tab to set the following two parameters:
• CGW: "Monitor parameter ECU24" change parameter to 027 447 57 27 “ECU24:SRS J1939
open not installed. See Fig. 13 .
• ICUc: "PID 0x43 (FTL Config)" "paramSRS" change parameter to 041 447 50 21, and verify
value is changed to "not available." See Fig. 14.
21.4 Press the "Send" button to write the parameter changes to the ICUC and CGW in the vehicle.
21.5 Once the parameter write is complete, click on the "Program Device" panel and click on "Connect to
Server" to upload updates to server. Disconnect the vehicle from DiagnosticLink.

02/19/2019

f120484

Fig. 13, Modifying the CGW Parameter
Page 14

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

02/19/2019

f120486

Fig. 14, Modifying the ICUc Parameter

IMPORTANT: This recall is not considered complete unless the stickers supplied in the kit are installed
in the vehicle. The stickers MUST be installed on both sides of the driver’s-side sun visor, and must
cover the existing airbag warning stickers.
22. Using two stickers supplied in the kit, install one on each side of the driver’s-side sun visor. The stickers
read as follows:
Non-RollTek vehicles - "STEERING WHEEL AIRBAG REMOVED, AND ROLLTEK DISABLED IF
EQUIPPED PER RECALL INT FL806." Note: This sticker was printed and kitted prior to the decision to not
disable the RollTek. Since this sticker is being applied to Non-RollTek vehicles, the RollTek portion of the
statement does not apply.
RollTek vehicles - "STEERING WHEEL AIRBAG REMOVED PER RECALL INT FL806." See Fig. 15.

Page 15

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

03/07/2019

f080205

Fig. 15, Installing the Stickers on the Sun Visor

23. Install the dash panels. Refer to Section 60.06, Subject 100 in the New Cascadia Workshop Manual for instructions.
24. Close the hood.
25. Connect the batteries.
26. Verify proper operation of the steering wheel switches and the electric horn, and make sure that the SRS
telltale on the instrument cluster is operating normally and does not remain illuminated after start up.
27. Completion stickers will NOT be applied for the interim repair; this step will occur in the final recall. Please
make sure the interim campaign claim is filed soon to avoid the repair being started by another dealer.

Page 16

Daimler Trucks
North America LLC

Recall Campaign

May 2019
INT FL806-01/02
NHTSA #19V-066
Transport Canada #19-054
INTERIM RECALL BULLETIN
SECOND REVISED NOTICE

ADDENDUM
Removed Air Bag Consolidation
NOTE: All containment costs to support storage and transportation of air bags removed as part of
Interim Recall FL806, should be itemized in the FL806 Final Campaign Claim with the appropriate
documentation.
Air bags removed during Interim Recall FL806 must be stored following EPA guidelines for Class 9
Hazardous Materials as described on Interim Recall FL806 Work Instructions step 15.2.
Air bags may also be transported to a pre‐arranged location for storage consolidation per EPA
regulations. Transporting air bags for storage consolidation is allowed only one time per airbag. All
secondary transfers of air bags must be done to the final consolidation location (details to be
provided in the Final Campaign Work Instructions).
Air bag quantities should not exceed 250 airbags and transportation containers should be labeled as
“Air Bag Waste ‐ Do Not Use”.
Containment materials used for storage and transportation of removed air bags must follow EPA
guidelines for Class 9 Hazardous Material. Containers meeting the regulation requirements can be
sourced locally or purchased from companies that specialize in material handling supplies such as
ULine (ULINE.COM).
The container size selection should be based on the number of air bags to be placed within the
container (i.e. small for single air bag or large for multiple air bag use). Air bags should be placed into
containers as described on step 15.2 of FL806 Work Instructions and should not exceed 50% of
container volume and container should be vented.
The packaging container should have Class 9 UN rating designation as listed below;
(1)UN Rating; 1A2, 1B2, 1N2, 1D, 1G, or 1H2, for drums.
(2)UN Rating; 3A2, 3B2, or 3H2, for jerricans.
(3)UN Rating; 4A, 4B, 4N, 4C1, 4C2, 4D, 4F, 4G, 4H1, or 4H2, for boxes.
A record (Bill of Lading, Delivery Receipt, etc.) must be created for all air bags being transported to
consolidation location and when received by a consolidation location. The records should be kept for
3 years. The record for each off‐site shipment must include, at a minimum, the name of transporter,
date of shipment, name & address of receiving facility, the type & quantity of the air bags in
shipment, and the date that the off‐site shipment was received.
All containment costs to support transportation and storage of air bags removed as part of Interim
Recall FL806, should be itemized and entered into a DTNA Campaign Claim with the appropriate
documentation.
Page 17