Oi
STORYTELLER

OVERLAND:

TSB-STO2023-003: Coolant Line
Securing Around Transfer Case

Rev07212023
Overview:

This document steps you through how to inspect the coolant lines in the area of concern to verify what
repairs are needed, if any, to prevent coolant leaks. Failure to inspect and repair properly as needed
could result in loss of coolant and, as a result, vehicle damage. Please contact Storyteller should you

have any questions or need any assistance with these instructions.

Safety Alert:

Do not perform these steps unless you feel comfortable doing so. The following inspection will be
performed under the van where components are likely to be hot. Only perform these steps once the
van has had adequate time to cool down. Exercise extreme caution when attempting to perform these
steps. Reach out to Storyteller Overland should you have any questions or concerns.

Flat Rate: 30 minutes

Applicable Vehicles:
All STO Mercedes Sprinter AWD MODEs
Tools and Supplies Needed:

e For Inspection:
o Flashlight
o camera (if needed)
© For only zip tie repair:
o Flush Cutters
o (2) high-temp heavy duty zip ties*

* Parts required for repair will be provided, as needed, by STO once photo proof of issue/damage is
provided.

Diagnostic Procedure:

1. Park the van in a safe area with adequate room to access underneath the van. Allow the van to
cool down to a safe working temperature. NOTE: Inspection will be performed under the van
where components are likely to be hot after driving. Only proceed to the next step once the
van has had adequate time to cool down. Exercise extreme caution when attempting to
perform these steps.

2. Inspect coolant lines under van

a. Locate the Rixen
heat exchanger
that is mounted to Figure 1
the chassis frame —
just behind the
driver side front

Locate Rixen heat
exchanger under the
van circled in the figure.
Follow the (2) coolant
lines between the
transmission and battery
box as pointed out with

tire as shown in
figure 1.

b. Follow the (2)
coolant lines from
the right side of
the heat
exchanger toward

an arrow.

the center of the
chassis and between the transmission and battery box. See figure 1

c. Closely inspect the coolant lines at the rear inboard corner of the battery box next to
the transfer case as shown in figure 2. Check whether the coolant lines are touching or
able to touch the transfer case. Figure 2 shows an example of what is NOT GOOD. We
do not want the coolant lines to be able to touch the transfer case at all. Check for any
signs of chafing, wear or damage to the coolant lines in this area and note what is
found on the Coolant Line Securing Checklist at the end of this document.

Transfer
Case y

Coolant lines are touching/able
to touch transfer case. This is
NOT GOOD

Figure 2

STORYTELLER OVERLAND. 1

Rev07212023

d. Continue to follow the coolant lines toward the front of the van. Closely inspect the (2)
coolant lines in the area between the battery box and the transmission from the transfer
case to the front differential above the front drive shaft. Verify there is a heavy duty zip
tie around the coolant lines above the transfer case in front of the white routing mount
for the fuel lines and there are at least (2) additional zip ties around the coolant lines
securing them to the chassis frame above the front drive shaft so that the coolant lines
are not allowed to contact the front drive shaft, transmission or transfer case. See
figures 3a and 3b.

e. Check for any signs of chafing, wear or damage to the coolant lines in this area and
note what is found on the Coolant Line Securing Checklist at the end of this document.

Zip Tie around

coolant lines

}

j
7
: t White Mount
> for fuel lines

} Rear Push Mount

22ip
Ties

around

Battery coolant

Heavy Duty
Box

Zip Tie around

coolant lines [A Y ati

/

dh.
G a
ps Differential Y

Transfer
Case

Figure 3b

f. If your coolant lines are not secured with zip ties and/or if your coolant lines appear to
be damaged in any way, document the issues seen in the checklist and take photos of
the damaged/unsecured coolant lines.

3. If no issues or concerns are found, complete the checklist at the end of this document, return a
copy to [email protected] and continue to EXPLORE ENDLESSLY!
4. If coolant lines are not secured and/or damage is found

a. Complete the checklist at the end of this document and take photos of the issues
found. Send the completed checklist and photos to [email protected]
to receive repair parts as necessary.

b. If coolant lines were not damaged but need to be secured, follow the repair steps in the
section below once repair parts have been received.

c. If the coolant lines have damage, additional repair instructions will be provided along
with the additional repair parts.

STORYTELLER OVERLAND. 2

Rev07212023

Repair Procedure:

5.

If the coolant lines did not show signs of wear or damage when inspected during the steps
above and simply need to be zip tied to prevent future risk, proceed to step 6 once repair parts
have been received. Note: Some locations may already have zip ties as detailed in the steps
below. You may either leave the current zip ties in place or replace them following each step
below.

Thread (1) of the zip tie mounts onto each of the (2) smaller zip ties so the head of the zip tie

faces the same direction as the push mount. See figure 4.

Figure 4

Install a push mount (once threaded onto the zip tie) into each of the (2) holes in the chassis
frame on the underside of the floor located between the transmission and battery box as
pointed out in figure 5a. Make sure the push mounts are pressed fully into each hole to provide
a secure hold.

Position the coolant lines up against the frame so they are prevented from making contact with
the front drive shaft. Wrap each zip tie around both coolant hoses and secure the zip ties so
they are snug against the coolant lines but will not restrict coolant flow. See figure 5b

Cut off the excess end of the zip tie using a pair of cutters and ensure the coolant lines do not
and are not able to make contact with the front drive shaft or any moving component.

2 Zip
Ties

around
coolant

Differential

Figure 5a Figure 5b

STORYTELLER OVERLAND.

Rev07212023

10. Secure 1 heavy duty zip tie around the
coolant lines and the hole in the chassis
frame member just in front of the white | Rear Push Mount

: : Zip Tie around
chassis hose mount that is located between

coolant lines

the battery box and the transfer case and
above the front driveshaft on the underside
of the van body floor. NOTE: Be sure to not
bundle the fuel lines that are routed
through the white mount with this zip tie. It , 8
. : aa Heavy Duty attery
is easiest to feed the zip tie between the ae Box

. Zip Tie around ~
fuel lines and the frame member first, then coolant lines AE ail

through the hole in the frame member and
then around the coolant lines to secure.
See figure 6

11. Cut off the excess end of the zip tie using a
pair of cutters and ensure the coolant lines

do not and are not able to make contact
with the front drive shaft or transfer case Figure 6
in this area.

12. Add the 2nd heavy duty zip tie around the
coolant lines and the negative (black) battery cable that comes out the rear inboard corner of
the battery box. Position the zip tie toward the top of the battery cable so it pulls the coolant
lines away from the transfer case considerably as shown in figure 7.

13. Reach out to STO should you have any further questions or concerns.

Black cable
coming out of
battery box
rear corner

Heavy Duty

Zip Tie around
coolant lines

Figure 7

STORYTELLER OVERLAND.

Rev07212023

Coolant Line Securing Checklist

Rev07212023

Instructions: Complete this checklist during the procedure outlined in the document "TSB-
$TO2023-003: Coolant Line Securing Around Transfer Case." Once the checklist and instructions have

been completed, supply completed form and necessary photos to Storyteller Overland via email at

[email protected]

Service Center Name: Date:
Name/Employee # of person(s) performing procedure:

Van Owner's Name: Van's VIN:

NOTE: If you answer yes to any of these questions, take photos to provide to Storyteller Overland
Step 2c: Are the coolant lines touching or able to touch the transfer case? Yes___ No.

Are there signs of chafing, wear or damage to the coolant lines in this area? Yes. No.

Description of chafing, damage or wear found:

Step 2d: Are there any zip ties missing in the locations detailed in this step? Yes. No.

Step 2e: Are there signs of chafing, wear or damage to the coolant lines in this area? Yes, No,

Description of chafing, damage or wear found:

Select one of the options below and initial on the line next to it:
O1 No issues or concerns found with the coolant lines. | am going to continue Exploring Endlessly!
1 Coolant lines were not damaged but needed to be secured per these instructions

1 Coolant lines have damage and | need further instructions.

STORYTELLER OVERLAND.

Rev07212023

A
STORYTELLER

OVERLAND:

TSB-STO2023-004: Coolant Line
Replacement-2

Rev07212023

Overview:

This document steps you through how to replace the coolant lines in the area of concern and contains a
checklist to complete and return back to [email protected]. Please contact Storyteller
should you have any questions or need any assistance with these instructions.

Safety Alert:

Do not perform these steps unless you feel comfortable doing so. The following steps will be
performed under the van where components are likely to be hot. Only perform these steps once the
van has had adequate time to cool down. Exercise extreme caution when attempting to perform these
steps. Reach out to Storyteller Overland should you have any questions or concerns.

Repair Time: 1 Hour

Applicable Vehicles:

All STO Mercedes Sprinter AWD MODEs

Tools and Parts Needed:

e Tools: © Parts*:

9 5/16" wrench o (2) 7 ft Coolant Hoses
o Drain pan o (10) Standard Zip ties
o Towels/Paper towels 0 (2) Zip Tie Push Mounts
o Scissors/Utility Knife o (2) Heavy Duty High-temp Zip Ties
o Flush cutters © 2 gallons Chassis Coolant
o Marker
o Funnel

* Parts required for repair will be provided to you by STO once photo proof of issue/damage has been
provided to STO.

Repair Procedure:

1. Park the van in a safe area with adequate room to access underneath the van. Allow the van to
cool down to a safe working temperature. NOTE: Repair will be performed under the van where
components are likely to be hot after driving. Only proceed to the next step once the van has
had adequate time to cool down. Exercise extreme caution when attempting to perform these
steps.

2. Inspect and take note of coolant line routing from under the van to the engine bay. This will
help you understand how to route the replacement hoses as detailed in these instructions.

a. Locate the Rixen heat exchanger that is mounted under the van to the chassis frame just
behind the driver side front tire as shown in figure 1.

b. Follow the (2) coolant lines from the right side of the heat exchanger toward the center
of the chassis and between the transmission and battery box. See figure 1

Figure 1

Locate Rixen heat

exchanger under the
van circled in the figure.
Follow the (2) coolant
lines between the

transmission and battery
box as pointed out with
an arrow.

}
| Battery

Box

c. Continue to follow the coolant lines in
the area between the battery box and
the transmission from the transfer case
to the front differential and above the
front drive shaft. See figure 2

d. From the front differential, the hoses