Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

Subject: FCCC MTG45/55 Gasoline Fuel Tanks
Models Affected: Specific Freightliner Custom Chassis MTG45/55
gasoline engine walk-in van chassis manufactured February 15,
2010, through April 30, 2012.

General Information
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Freightliner Custom Chassis
Corporation, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.
Until the final Recall remedy is available, this interim procedure may be performed, if needed, on eligible
vehicles. Vehicles that are not experiencing a failure do not need this procedure and it should not be
performed. Do not use completion stickers for this repair.
Certain gasoline fuel tanks may experience cracks in the tank skin or welds due to fatigue, leading to a possible
leak of gasoline or fumes. A fuel leak, when in the presence of an ignition source, could increase the risk of a fire.
When a customer reports a leaking fuel tank, the fuel tank will be replaced.

Work Instructions
Please refer to the attached work instructions. Before beginning work, confirm whether a vehicle is eligible for an
interim Recall repair by checking the VIN in OWL. For those who do not have access to OWL, go to Warranty
Support Center/Campaigns/Interim Recall Inquiry and enter the vehicle serial number and make. Do not use
completion stickers for this repair.

Replacement Parts
Obtain parts for this interim Recall repair by ordering from your facing Parts Distribution Center.
Table 1 - Interim Repair Parts for INT FL640
NOTE: The existing washers and fuel line clips will be reused. An allowance of up to $15.00 may be used for
miscellaneous items such as enamel, dialectric grease, tie straps, etc. that might be needed. If fuel line clips must
be replaced, contact the Freightliner Custom Chassis Service Center and clips will be provided. Order fuel tanks
on a Warranty Order.
Campaign Number

INT FL640-01

Part Description

Part Number

Qty.

Replaces A03-39362-000
TANK-FUEL,40,BTR,PLN

A03-39362-000

1 ea

Replaces A03-39036-000, A03-38866-000, or
A03-39186-000
TANK-FUEL,40G,BTR,LH

A03-39186-000

1 ea

Use for all Replacements
SCREW-CAP HEX 1/2-13

23-11751-700

4 ea

Use for all Replacements
NUT HEX PT 1/2 13 C

23-13833-108

4 ea

Use for all Replacements
TIESTRAP

TYC DCT110HIR

1 ea

Table 1

Removed Parts
Please follow Warranty Failed Parts Tracking shipping instructions for the disposition of all removed parts.

Page 1

Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

Labor Allowance
Table 2 - Labor Allowance
NOTE: All claims for Interim FL640 will be for replacement of a fuel tank and will include all three SRTs listed
below.
Procedure

Time Allowed
(hours)

SRT Code

Replace gasoline fuel tank

2.1

996-0895A

Fuel tank, verified destruction

0.5

204-6025A

Fuel tank photos

0.2

939-6030A

Campaign Number

INT FL640-01

Table 2

Claims for Credit
This interim Recall repair is performed only when a failure is present, do not perform the interim repair
if there is no failure. Do not use completion stickers for this repair. You will be reimbursed for your parts,
labor, and handling by submitting your claim through the Warranty system within 30 days of completing an interim
Recall repair. Please reference the following information in OWL:
NOTE: If you do not have access to OWL, submit a WSC inquiry requesting instructions for QuickClaim (Warranty
Support Center/Campaigns/Campaign Inquiry).
Claims in OWL
Claim Type

Request Type

OWL Interim Campaign
Number

PFP

VMRS Code
Cause Code

Recall

Payment

INT FL640-01

25-FL640-000

044-001-001
A1-Campaign

Table 3

• Claim type is Recall and Request type is Payment.
• In the Campaign field, enter INT FL640-01.
• Use the retrieve button to populate the claim. If needed, fill in any items not automatically included. NOTE:
The existing washers and fuel line clips will be reused. An allowance of up to $15.00 may be used for
miscellaneous items such as enamel, dialectric grease, tie straps, etc. that might be needed. If fuel line clips
must be replaced, contact the Freightliner Custom Chassis Service Center and clips will be provided . Order
fuel tanks on a Warranty Order .
• The normal fuel tank scrapping procedure is required (refer to the Warranty Manual, Section 6.25 Fuel
Tanks, for further information):
• Scrapping of Fuel Tank form (Form WAR110), attached to the claim.
• Photos of the removed fuel tank, attached to the claim. A clear photo of the manufacturer’s label must
be included.
• Destruction of the fuel tank.
• If additional parts, labor, or other charges beyond what is outlined in this bulletin were needed, stop and
submit as a Recall Pre-Approval Request.

Page 2

Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

IMPORTANT: Before beginning work, confirm whether a vehicle is eligible for an interim Recall repair by checking
the VIN in OWL. For those who do not have access to OWL, go to Warranty Support Center/Campaigns/Interim
Recall Inquiry and enter the vehicle serial number and make.
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.
The interim letter notifying vehicle owners is included for your reference.

Page 3

Recall Campaign

Daimler Trucks
North America LLC

Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

Copy of Interim Notice to Owners
Subject: FCCC MTG45/55 Gasoline Fuel Tanks
For the Notice to U.S. Customers: This notice is sent to you in accordance with the requirements of the National
Traffic and Motor Vehicle Safety Act.
For the Notice to Canadian Customers: This notice is sent to you in accordance with the Canadian Motor
Vehicles Safety Act.
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Freightliner Custom Chassis, has
decided that a defect which relates to motor vehicle safety exists on specific Freightliner Custom Chassis MTG45/55
gasoline engine walk-in van chassis manufactured February 15, 2010, through April 30, 2012.
Certain gasoline fuel tanks may experience cracks in the tank skin or welds due to fatigue, leading to a possible
leak of gasoline or fumes. A fuel leak, when in the presence of an ignition source, could increase the risk of a fire.
This is the first of two notices you will receive regarding this subject. This letter is to inform you of an upcoming
Recall and provide important information regarding steps you may take in the interim. Daimler Trucks is currently
developing a remedy and will notify you when it is available. When you receive the second notice, please contact
your authorized Daimler Trucks dealer to schedule the Recall for your vehicle.
Before the remedy is available, there are steps you can take to reduce the risk of your vehicle developing this
condition. As part of your daily pre-trip inspection, inspect the fuel tank. If you find evidence of a leak – gasoline
on the surface (not resulting from filling the tank) or signs of gasoline dripping from the tank or on the ground
under the tank – please take your vehicle to an authorized Daimler Trucks location to have the fuel tank replaced
at no charge. If no signs of a leak are found, there is no further action for you to take until you receive the second
notice.
If you do not own the vehicle that corresponds to the identification number(s), which appears on the Recall Notice,
please return the notice in the postage-paid envelope with any information you can furnish that will assist us in
locating the present owner.
For the Notice to U.S. Customers: If you have questions about this Recall, please contact the Warranty
Campaigns Department at (800) 547-0712, 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. You may wish to submit a complaint to the Administrator, National Highway Traffic Safety
Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888)
327-4236 (TTY: 800-424-9153); or to http://www.safercar.gov.
For the Notice to Canadian Customers: If you have questions about this Recall, please contact the Warranty
Campaigns Department at (800) 547-0712, 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.
We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle
safety.

WARRANTY CAMPAIGNS DEPARTMENT
Enclosure

Page 4

Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

Work Instructions
Subject: FCCC MTG45/55 Gasoline Fuel Tanks
Models Affected: Specific Freightliner Custom Chassis MTG45/55
gasoline engine walk-in van chassis manufactured February 15,
2010, through April 30, 2012.
IMPORTANT: Perform this interim Recall repair only when a failure is present, do not perform the interim
repair if there is no failure. Do not use completion stickers for this repair.
NOTE: The existing washers and fuel line clips will be reused. An allowance of up to $15.00 may be used for
miscellaneous items such as enamel, dialectric grease, tie straps, etc. that might be needed. If fuel line clips must
be replaced, contact the Freightliner Custom Chassis Service Center and clips will be provided. Order fuel tanks
on a Warranty Order.

Fuel Tank Replacement
1. Has the customer reported a fuel tank leak?
If there is no leak, stop and do not perform this procedure, no work is needed at this time.
If there is a leak, continue 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. With the engine running, remove the fuel pump fuse to relieve fuel pressure in the fuel line, and let the engine
run down.
The fuel pump fuse is located in the power distribution module (PDM) closest to the brake fluid reservoir.
4. Disconnect the batteries at the negative posts.

WARNING
Do not drain fuel near, or expose fuel vapor to, open flame or intense heat. To do so might cause a fire,
which could lead to serious personal injury or property damage.
5. Remove the fuel cap and retain it for later use.
6. Remove as much fuel as possible, storing it in a clean container, and protecting it from contamination.
7. In the cargo area, remove the access panel, if so equipped, to gain access to the top of the fuel tank.
8. Loosen the fill hose clamp and slide it up the fuel filler hose. Remove the fuel filler hose.
9. Disconnect the electrical connections on the fuel tank header. See Fig. 1.
10. Carefully remove the plastic secondary clip on the fuel line connector and set it aside. Push the fuel line
connector toward the fuel tank header and disengage the fuel line.

CAUTION
Fuel will leak from the fuel hose when it is removed. Wear safety glasses to avoid personal injury.
11. Push the secondary clips in to disengage them from the vent hoses. If the clips fail to release, blow any
debris out of the release mechanism and repeat the process. Once the secondary clips have been removed,
disconnect the fuel and vent hoses. See Fig. 1.

Page 5

Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

1

2
03/11/2013

f470601

1. Fuel Tank Header
2. Ground Strap (one on each side of tank)
Fig. 1, Fuel Tank Electrical Connections and Hoses

12. Raise the vehicle enough to remove the fuel tank.
13. Remove the ground straps from both sides of the fuel tank.
14. Using a transmission jack, support the fuel tank.
15. Remove the fuel tank support straps and carefully lower the fuel tank from the chassis frame rails.
16. Scrap the fuel tank per the Warranty Manual, Section 6.25 Fuel Tanks.
16.1

Complete the Scrapping of Fuel Tank form (Form WAR110) and attach it to the claim.

16.2

Take the required photos and attach them to the claim. A clear photo of the manufacturer’s label must
be included, see Fig. 2

16.3

Destroy the fuel tank by cutting off each end of the fuel tank.

17. Using a transmission jack, position the new fuel tank assembly underneath the vehicle. Ensure that the fuel
filler neck is properly positioned. Lift the fuel tank into position.

NOTICE
Do not collapse the isolator springs. Doing so will damage the springs.
18. Using the fuel tank support straps and new fasteners, attach the new fuel tank assembly to the chassis. See
Fig. 3. Using a distance from the base of the washer under the spring to the top of the bracket, tighten the
nuts 111±3 mm; do not collapse the isolator springs.
19. Install the fill hose clamp on the fuel filler hose and hand tighten.
20. Inspect the electrical connections to the pump and sender. Remove any corrosion and apply dielectric grease.
21. Connect the electrical connections on the fuel tank header.
22. Inspect the ground strap connections. Remove any corrosion and apply dielectric red enamel, then connect
the ground straps. Tighten 84 lbf1in (949 N1cm).

Page 6

Daimler Trucks
North America LLC

Recall Campaign
Arpil 2013
INT FL640-01
NHTSA #13V-023
INTERIM RECALL BULLETIN

1

03/28/2013

2

f470604

3

Fig. 2, Manufacturer's Label
03/11/2013

f470602

1. Frame Rail
2. Fuel Tank
3. Lower Fuel Tank Support Straps
Fig. 3, Lower Fuel Tank Support Straps

23. Ensure that the fuel and vent hoses are clean and free of contaminates. Install the fuel and vent hoses on the
fuel tank as follows.
23.1

Place a few drops of motor oil on the end of the vent tubes.

23.2

Install the two vent connectors on the tank header until the retainer snaps in place and the connector
comes to a stop. Pull the connector and ensure it is locked in place.

23.3

Use the plastic secondary clip that was removed earlier and install the fuel line. Pull the connector and
ensure it is locked in place.

24. Add the fuel that was removed earlier to the fuel tank and install the fuel cap.
25. Install the fuel pump fuse in the PDM.
26. Connect the batteries.
27. Turn the ignition to the ON position (do not start the vehicle) and prime the fuel system, while checking for
leaks.
28. Install the access panel in the cargo area.
29. Lower the vehicle.

Page 7