FL922_V4 Service Bulletin/Repair Instructions

Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E

(Revised November 2023)
Emissions Recall: Freightliner Cascadia and

Western Star 49X Exhaust Support Bracket

Models Affected: Specific model year 2022 Freightliner Cascadia

and Western Star 49X vehicles, equipped with DD15 engines,

manufactured January 4, 2021, through January 17, 2022.
General Information

4TH REVISION: It is no longer required to replace the bellows assembly, if replaced.

3RD REVISION: Some vehicles were moved from group C to new groups D and E. The work instructions for

Group C have been updated. The parts table has been updated.

2ND REVISION (no longer applies): A nut has been added to the parts table. If using clamp A04-28055-001,

then use 1/2’-inch nut 23-13833-108. If using clamp A04-28055-002, then use 12 mm nut, 23-14072-112.

1ST REVISION: SRT 996-R140A has been corrected from 0.2 hours to 0.1 hours.

The U.S. Environmental Protection Agency has determined that the engines/equipment mentioned above may

be emitting pollutants in excess of the Federal emission standards (and/or California standards) as defined in

Title 40 of the Code of Federal Regulations. These emission standards were established to protect the public

health or welfare from air pollution. To ensure customers’ full protection under the emission warranty on these

engines/equipment by Federal law, and customers’ rights to participate in future recalls, it is recommended that

these engines/equipment be serviced as soon as possible. Failure to do so could be considered improper

maintenance.

There are approximately 53,741 vehicles involved in this emissions recall.

On certain Freightliner Cascadia and Western Star 49X vehicles with DD15 engines, the exhaust pipe between

the turbocharger outlet and the aftertreatment system (ATS) inlet may experience failure due to overall

deflection that exceeds the limits of the bellows under certain conditions. Subsequently, the exhaust pipe

assembly, including the bellows, can separate and slip out at the ATS inlet joint. This can result in untreated

engine exhaust leaking into the atmosphere. Additionally, the bellows and/or its inner liner may also be

damaged under these circumstances.

If this failure occurs, an extremely loud noise will be heard from the exhaust. This extreme noise will be

noticeable to the driver and will make driving difficult due to the truck-cab interior noise levels. Additionally,

multiple OBD faults could be triggered, further alerting the driver to discontinue driving.

All affected vehicles will have an exhaust pipe support bracket and pipe clamp installed. Additionally, the

bellows will be inspected for cracks or discoloration, and the exhaust pipe assembly will be replaced if

necessary. Repairs will be performed by Daimler Truck North America authorized repair facilities.

Additional Repairs

NOTE: Please be aware that the FL922 suspect population may overlap with the truck population affected by

DDC 22TS-03 which is related to the soot sensor harness connector. Although not required, the technician may

choose to reference DDC 22TS-03 and perform the inspection while the chassis fairings are removed for the

FL922 exhaust bracket modification.

Dealers must complete all outstanding Recall and 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.
Page 1
Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E

(Revised November 2023)
Work Instructions

Please refer to the attached work instructions. Prior to performing the campaign, check the vehicle for a

completion sticker (Form WAR260).
Replacement Parts

Replacement parts are now available and can be obtained by ordering the part numbers listed below from your

facing Parts Distribution Center.

If our records show your dealership has ordered any vehicles involved in recall number FL922, a list of the

customers and vehicle identification numbers will be available on DTNAConnect.com. Please refer to this list

when ordering parts for this recall.

Table 1 - Replacement Parts for FL922

NOTE: On rare occasions, estimated at 1% of the population, the bellows assembly may need to be replaced.

In this situation, please refer to PartsPro to obtain the part numbers for the bellows assembly, spherical gasket,

and axial slip clamp kit prior to ordering. Inspection and replacement of the bellows assembly is included in the

work instructions.

Recall Number
FL922 A
FL922 B
FL922 C
FL922 D
(Continued on next page)
Page 2
Part Number
Part Description
Qty.
04-36065-000

A04-28055-002

23-14072-112
BRKT-ATS IN, GATS 2.0, P4, DD15

CLAMP ASSY-EXH PIPE,4IN,SST

NUT-HEX,LKG,ZNAL,BK,M12X1.5
1 ea

1 ea

1 ea
23-14067-120

23-14091-004
BOLT-HEX,ZNAL,BK,M16X1.5X120

WSHR-STL,HDND,ZNAL,BK,.500
1 ea

1 ea
23-14283-075

23-14091-007
BOLT-HEX,PC10.9,PO,M16X1.5X75

WSHR-STL,HDND,ZNAL,BK,.625
1 ea

4 ea
23-14451-116

04-36072-000

A04-28055-002

23-14072-112
NUT-HEX,LKG,VLH BLU,M16X1.5

BRKT-ATS IN,GATS 2.0,49X

CLAMP ASSY-EXH PIPE,4IN,SST

NUT-HEX,LKG,ZNAL,BK,M12X1.5
23-14283-130

23-14091-004
BOLT-HEX,PC10.9,PO,M16X1.5X130

WSHR-STL,HDND,ZNAL,BK,.500
1 ea

1 ea
23-14283-080

23-14091-007

23-14451-116

23-14091-004

04-36073-000

A04-28055-002

23-14072-112

23-14283-100

23-14091-007

23-14451-116

23-14091-004

04-36073-000

A04-28055-002

23-14072-112

23-14091-007

23-14283-100

23-14451-116
BOLT-HEX,PC10.9,PO,M16X1.5X80

WSHR-STL,HDND,ZNAL,BK,.625

NUT-HEX,LKG,VLH BLU,M16X1.5

WSHR-STL,HDND,ZNAL,BK,.500

BRKT-ATS IN,GATS 2.0,49X

CLAMP ASSY-EXH PIPE,4IN,SST

NUT-HEX,LKG,ZNAL,BK,M12X1.5

BOLT-HEX,PC10.9,PO,M16X1.5X100

WSHR-STL,HDND,ZNAL,BK,.625

NUT-HEX,LKG,VLH BLU,M16X1.5

WSHR-STL,HDND,ZNAL,BK,.500

BRKT-ATS IN,GATS 2.0,49X

CLAMP ASSY-EXH PIPE,4IN, SST

NUT-HEX,LKG,ZNAL,BK,M12X1.5

WSHR-STL,HDND,ZNAL,BK,.625

BOLT-HEX,PC10.9,PO,M16X1.5X100

NUT-HEX,LKG,VLH BLU,M16X1.5
1

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Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E

(Revised November 2023)
Recall Number
FL922 E
ALL GROUPS
Part Number
Part Description
Qty.
23-14091-004

04-36073-000
WSHR-STL,HDND,ZNAL,BK,.500

BRKT-ATS IN,GATS 2.0,49X
1 ea

1 ea
A04-28055-002
CLAMP ASSY-EXH PIPE,4IN, SST
1 ea
23-14072-112

23-14091-007

23-14283-100
NUT-HEX,LKG,ZNAL,BK,M12X1.5

WSHR-STL,HDND,ZNAL,BK,.625

BOLT-HEX,PC10.9,PO,M16X1.5X100
1 ea

2 ea

1 ea
23-14451-116
NUT-HEX,LKG,VLH BLU,M16X1.5
2 ea
RED

WAR260
HIGH-STRENGTH THREAD LOCKER

BLANK COMPLETION STICKER
N/A

1 ea
Table 1
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

Recall

Number

FL922 A-E

(All Groups)
FL922 A
Procedure
Time Allowed

(hours)
SRT Code
Corrective Action
0.1
996-R140A
06-Inspect
1.5
996-R140B
12-Repair Recall/Campaign
1.7
996-R140C
12-Repair Recall/Campaign
1.7
996-R140F
12-Repair Recall/Campaign
1.3
996-R140D
12-Repair Recall/Campaign
1.5
996-R140E
12-Repair Recall/Campaign
1.5
996-R140G
12-Repair Recall/Campaign
Inspect For Exhaust Bracket

(No Further Work Required if Present)

Install Exhaust Bracket

Install Exhaust Bracket,

Remove and Replace Exhaust Pipe

Install Exhaust Bracket,

Remove and Reuse Exhaust Pipe

Install Exhaust Bracket
FL922 B-E
Install Exhaust Bracket,

Remove and Replace Exhaust Pipe

Install Exhaust Bracket,

Remove and Reuse Exhaust Pipe
Table 2
IMPORTANT - Before Beginning Work:

• Check OWL to ensure the vehicle is involved and the recall has not previously been completed.

• Check the vehicle for a recall completion sticker.

IMPORTANT - After Repair is Complete:

• Attach a red completion sticker (Form WAR260) to the base completion label (Form WAR259). If the

vehicle does not already have a base completion label, clean a spot on the appropriate location of the

vehicle, and attach a base completion label, prior to installing the completion sticker.
Page 3
Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E

(Revised November 2023)
Claims for Credit

You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting a

claim. Please reference the following information in OWL:

• All claims must be submitted within 30 days of the repair date.

• Claim type is Recall Campaign.

• In the FTL Authorization field, enter the recall number and appropriate condition code (e.g. FL922A,

FL922B, etc.).

• In the Primary Failed Part Number field, enter 25-FL922-000.

• In the Parts field, enter the appropriate part numbers as shown in the Replacement Parts Table.

• In the Labor field, enter the appropriate SRT from the Labor Allowance Table. Administrative time will be

included automatically as SRT 939-6010A for 0.3 hours.

• For OWL, the VMRS Component Code is F99-999-005 and the Cause Code is A1 - Campaign.

• U.S. and Canada -- Reimbursement for Prior Repairs. When a customer asks about reimbursement,

please do the following:

• Accept documentation of the previous repair.

• Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement. (See the "Copy of Owner Letter" section of this bulletin for reimbursement guidelines for this

recall.)

• Include the charges for the previous repair on the claim in the Other Charges section.

• In the claim story, note that the claim includes customer reimbursement.

• Retain the documentation and provide it to Warranty Campaigns or Claims Processing if requested.

• When your claim is paid, reimburse the customer the appropriate amount.

U.S. and Canadian dealers, contact the Warranty Campaigns Department via the Warranty Support Center at

DTNAConnect.com/WSC if you have any questions or need additional information. Export distributors, submit a

WSC ticket or contact your International Service Manager.

To return excess inventory related to this campaign, U.S. dealers must submit a Parts Authorization Return

(PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing PDC. All parts/kits must be in

resalable condition. PAR requests must include the original purchase invoice number. Export Distributors:

Excess inventory is not returnable.

The letter notifying U.S. and Canadian vehicle owners is included for your reference.

Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code,

Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to

you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie

evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day

period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the

vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in

full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless

all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the

lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors

and retail outlets within five working days.
Page 4
Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E
Copy of Notice to Owners

Emissions Recall: Freightliner Cascadia and

Western Star 49X Exhaust Support Bracket

Your vehicle may be equipped with an exhaust system that violates (California or California and Federal)

standards and regulations.

The U.S. Environmental Protection Agency has determined that your engine/equipment may be emitting

pollutants in excess of the federal emission standards (and/or California standards) as defined in Title 40 of the

Code of Federal Regulations. These emission standards were established to protect the public health or welfare

from air pollution. To ensure your full protection under the emission warranty on your engine/equipment by

federal law, and your right to participate in future recalls, we recommend you have your engine/equipment

serviced as soon as possible. We may consider your not servicing it to be improper maintenance.

Daimler Truck North America LLC (DTNA), on behalf of its Freightliner Trucks division, and wholly owned

subsidiary Western Star Truck Sales, Inc., is initiating emissions recall FL922A-C to modify specific model year

2022 Freightliner Cascadia and Western Star 49X vehicles, equipped with DD15 engines, manufactured

January 4, 2021, through January 17, 2022.

On certain Freightliner Cascadia and Western Star 49X vehicles with DD15 engines, the exhaust pipe between

the turbocharger outlet and the aftertreatment system (ATS) inlet may experience failure due to overall

deflection that exceeds the limits of the bellows under certain conditions. Subsequently, the exhaust pipe

assembly, including the bellows, can separate and slip out at the ATS inlet joint. This can result in untreated

engine exhaust leaking into the atmosphere. Additionally, the bellows and/or its inner liner may also be

damaged under these circumstances.

If this failure occurs, an extremely loud noise will be heard from the exhaust. This extreme noise will be

noticeable to the driver and will make driving difficult due to the truck-cab interior noise levels. Additionally,

multiple OBD faults could be triggered, further alerting the driver to discontinue driving.

All affected vehicles will have an exhaust pipe support bracket and pipe clamp installed. Additionally, the

bellows will be inspected for cracks or discoloration, and the exhaust pipe assembly will be replaced if

necessary. Repairs will be performed by Daimler Truck North America authorized repair facilities.

Please contact an authorized DTNA dealer to arrange to have the Recall performed and to ensure that parts

are available at the dealership. To locate a dealer, search online at https://northamerica.daimlertruck.com/

contact-us (scroll to bottom) / Locate a Dealer (scroll to bottom). The Recall will take approximately two hours

and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at

URL: https://dtna-dlrinfo.prd.freightliner.com: 48518/VinLookup/vin-module/getVinLookupPage.

If you reside in the State of California, the repairing facility will provide a certificate showing your vehicle has

had the Recall completed. This certificate may be required as a condition of vehicle registration or operation.

If you do not own the vehicle that corresponds to the identification number(s) on the Recall Notification, please

return the notification to the Warranty Campaigns Department with any information you can furnish that will

assist us in locating the present owner. If you have leased this vehicle, Federal law requires that you forward

this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law requires that

you forward this notice to your distributors and retail outlets within five working days. If you have paid to have

this recall condition corrected prior to this notice, you may be eligible to receive reimbursement. Please see the

reverse side of this notice for details.

If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712,

e-mail address [email protected]. For other concerns, you may contact the Customer

Assistance Center at (800) 385-4357.

We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle

emissions compliancy.

WARRANTY CAMPAIGNS DEPARTMENT

Enclosure

Page 5
Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E
Reimbursement to Customers for Repairs

Performed Prior to Recall

If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.

Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the

repair would have cost if completed by an authorized Daimler Truck North America LLC dealer. The following

documentation must be presented to your dealer for consideration for reimbursement.

Please provide original or clear copies of all receipts, invoices, and repair orders that show:

• The name and address of the person who paid for the repair

• The Vehicle Identification Number (VIN) of the vehicle that was repaired

• What problem occurred, what repair was done, when the repair was done

• Who repaired the vehicle

• The total cost of the repair expense that is being claimed

• Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt)

Reimbursement will be made by check from your Daimler Truck North America LLC dealer.

Please speak with your Daimler Truck North America LLC authorized dealer concerning this matter.
Page 6
Daimler Truck

North America LLC
Recall Campaign
May 2022

FL922A-E

(Revised November 2023)
Work Instructions

Emissions Recall: Freightliner Cascadia and

Western Star 49X Exhaust Support Bracket

Models Affected: Specific model year 2022 Freightliner Cascadia

and Western Star 49X vehicles, equipped with DD15 engines,

manufactured January 4, 2021, through January 17, 2022.

4TH REVISION: It is no longer required to replace the bellows assembly, if replaced.

3RD REVISION: Some vehicles were moved from group C to new groups D and E. The work instructions for

Group C have been updated. The parts table has been updated.

2ND REVISION (no longer applies): A nut has been added to the parts table. If using clamp A04-28055-001,

then use 1/2’-inch nut 23-13833-108. If using clamp A04-28055-002, then use 12 mm nut, 23-14072-112.

1ST REVISION: SRT 996-R140A has been corrected from 0.2 hours to 0.1 hours.

The following procedures are to be performed under the scope of this campaign:

• Support Bracket Inspection and Exhaust Pipe Bellows Inspection

• Exhaust Pipe Removal and Internal Inspection (if required)

• Exhaust Pipe Replacement (if required)

• Support Bracket Installation

• Support Clamp Installation

NOTE: Please be aware that the FL922 suspect population may overlap with the truck population affected by

DDC 22TS-03 which is related to the soot sensor harness connector. Although not required, the technician may

choose to reference DDC 22TS-03 and perform the inspection while the chassis fairings are removed for the

FL922 exhaust bracket modification.
FL922 A

(FL922 B: Go to page 17. FL922 C: Go to page 24. FL922 D: Go to page 31. FL922 E: Go to page 39.)
Exhaust Pipe Bellows Inspection (FL922A)

1. Check the base label (Form WAR259) for a completion sticker for FL922 (Form WAR260) indicating this

work has been done. The base label is usually located on the passenger door about 12 inches (30 cm) below the door latch. If a sticker is present, no work is needed. If there is no sticker, proceed with the next

12 3 4

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