Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)

Emissions Recall: Cummins DEF Sensor Shortage
Models Affected: Specific model years 2016-2022 Freightliner
Cascadia, Business Class M2, 108SD, 114SD, 122SD; Western
Star 4700, 4900, 49X; Thomas Built Buses EFX, HDX, MVP-EF,
Saf-T-Liner C2 vehicles; and Freightliner Custom Chassis MB,
S2C, XB, MT45, MT55, S2RV, XC, manufactured January 7, 2016,
through September 28, 2021, equipped with Cummins engines.

General Information
REVISION: Some vehicles formerly in Group F have been moved to Group G and have been assigned a new
part number as specified in Table 1. An SRT for ’Calibration Code Only: Update or Confirm’ has been added,
as shown in Table 2, to be used when a new DEF header is not required. There have been some other minor
changes to the work instructions and SRT times.
Due to a market shortage, Diesel Exhaust Fluid (DEF) sensors were unavailable. Pursuant to an agreement
with the U.S. Environmental Protection Agency, California Air Resources Board, and certifying emission
regulators in Canada, certain vehicles with Cummins engines were equipped with engine software that was
temporarily modified to account for continued operation without the required DEF sensors. The conditions of
that agreement required recalling those engines to install DEF sensors and corresponding software once the
sensors became available. 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.
The DEF header will be inspected, and if required, a new DEF header will be installed, and the engine software
will be updated. Repairs will be performed by Daimler Truck North America authorized service facilities.
There are approximately 5,946 vehicles involved in this campaign.
Additional Repairs
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.

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 number(s) listed below from
your facing Parts Distribution Center (PDC).
If our records show your dealership has ordered any vehicles involved in campaign number FL974, a list of the
customers and vehicle identification numbers will be available on the DTNA Portal via OWL. Please refer to this
list when ordering parts for this recall.

Page 1

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)
Table 1 - Replacement Parts for FL974
Campaign Number

Part Number

Part Description

Qty.

FL974 A

04-31354-004

HEADER-SSI,CONC,6 BOLT,CMNS

1 ea

FL974 B-C
FL974 D

04-36003-000
04-36002-000

HEADER-DEF,10G,SSI
HEADER-DEF,11.5G,SSI

1 ea
1 ea

FL974 E

04-36004-000

HEADER-DEF,15G,SSI

1 ea

FL974 F

04-31353-005

HEADER-SSI,CONC,SAE FLG,CMNS

1 ea

FL974 G
ALL GROUPS

04-31353-006
WAR260

HEADER-SSI,CONC,SAE,CMNS,GEN 2
COMPLETION STICKER

1 ea
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
Campaign
Number

Procedure

Time Allowed
(hours)

SRT Code

Corrective Action

FL974 A
FL974 B

Install DEF Header 6-Gal, Update Software
Install DEF Header 10-Gal, Update Software

2.2
2.5

996-R211A
996-R211B

12-Repair Recall/Campaign
12-Repair Recall/Campaign

FL974 C-E
FL974 F-G

Install DEF Header 10/11.5/15 Gal, Update Software
Install DEF Header 13/23 Gal, Update Software

2.4
2.7

996-R211C
996-R211D

12-Repair Recall/Campaign
12-Repair Recall/Campaign

ALL GROUPS

Calibration Code Only: Update or Confirm

0.5

996-R211E

12-Repair Recall/Campaign

Table 2

IMPORTANT: When the recall has been completed, locate the base completion label in the appropriate location
on the vehicle, and attach the red completion sticker provided in the recall kit (Form WAR260). 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 recall kit is not required or there is no completion sticker in the
kit, write the recall 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 Recall Campaign.
• In the FTL Authorization field, enter the campaign number and appropriate condition code (e.g. FL974-A,
FL974-B, etc.).
• In the Primary Failed Part Number field, enter 25-FL974-000.
• In the Parts field, enter the appropriate part number(s) as shown in the Replacement Parts Table.
• In the Labor field, first enter the appropriate SRT from the Labor Allowance Table. For administrative time,
enter SRT 939-6010A for 0.3 hours (0.4 hours for RVs).
• 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:

Page 2

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)
• Accept the 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.)
• Submit a Campaign Pre-Approval inquiry to the Warranty Campaigns Department for a decision
and authorization number.
• Include the approved amount on your claim in Other Charges section.
• In the claim story, first note the authorization number and that the claim includes a 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.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the
campaign has not been previously completed. Also, check for a completion sticker prior to beginning work.
U.S. and Canadian dealers, contact the Warranty Campaigns Department via the Warranty Support Center
(WSC), located on the DTNA Portal., if you have any questions. Export distributors, submit a WSC ticket or
contact your International Service Manager.
U.S. and Canadian Dealers: To return excess kit 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 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 3

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-F

Copy of Notice to Owners
Emissions Recall: Cummins DEF Sensor Shortage
US: Your vehicle may be equipped with an exhaust system that violates Federal and/or California standards
and regulations. CAN: This notice is sent to you in accordance with the requirements of the Canadian
Environmental Protection Act, 1999.
Due to a market shortage, diesel exhaust fluid (DEF) sensors were unavailable. Pursuant to an agreement with
the U.S. Environmental Protection Agency, California Air Resources Board, and certifying emission regulators in
Canada, certain vehicles with Cummins engines were equipped with engine software that was temporarily
modified to account for continued operation without the required DEF sensors. The conditions of that agreement
required recalling those engines to install DEF sensors and corresponding software once the sensors became
available. 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.
Daimler Truck North America LLC (DTNA), on behalf of its Freightliner Trucks division, and wholly owned
subsidiaries Western Star Truck Sales, Freightliner Custom Chassis Corporation (FCCC), and Thomas Built
Buses (TBB), is initiating emissions recall FL974 A-F to modify specific model years 2016-2022 Freightliner
Cascadia, Business Class M2, 108SD, 114SD, 122SD; Western Star 4700, 4900, 49X; TBB EFX, HDX,
MVP-EF, Saf-T-Liner C2 vehicles; and FCCC MB, S2C, XB, MT45, MT55, S2RV, XC chassis’, manufactured
January 7, 2016, through September 28, 2021, equipped with Cummins engines.
A new DEF header will be installed, and the engine software will be updated. Repairs will be performed by
Daimler Truck North America authorized service facilities.
Vehicle performance, other engine components, or drivability are not affected. The DEF sensor is used to
indicate how much DEF is left in the tank. Failure to show an accurate level of DEF may lead to emission
concerns.
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 down to ’Locate a Dealer’, and search for a Freightliner location. The recall will take
approximately two to two and a half hours and will be performed free of charge. 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 that 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), which appears 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,
7 a.m. to 4 p.m. Pacific Time, Monday through Friday, e-mail: [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 being
compliant with motor vehicle emissions regulations.
WARRANTY CAMPAIGNS DEPARTMENT
Enclosure
Page 4

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-F

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 5

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)

Work Instructions
Emissions Recall: Cummins DEF Sensor Shortage
Models Affected: Specific model years 2016-2022 Freightliner
Cascadia, Business Class M2, 108SD, 114SD, 122SD; Western
Star 4700, 4900, 49X; Thomas Built Buses EFX, HDX, MVP-EF,
Saf-T-Liner C2 vehicles; and Freightliner Custom Chassis MB,
S2C, XB, MT45, MT55, S2RV, XC, manufactured January 7, 2016,
through September 28, 2021, equipped with Cummins engines.
REVISION: Some vehicles formerly in Group F have been moved to Group G and have been assigned a new
part number as specified in Table 1, page 2. An SRT for ’Calibration Code Only: Update or Confirm’ has been
added, as shown in Table 2, page 2, to be used when a new DEF header is not required. There have been
some other minor changes to the work instructions and SRT times.

FL974 A — FTL and WST 6-Gallon Tank Header
1. Check the base label (Form WAR259) for a completion sticker for FL974 (Form WAR260) 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. If a recall completion 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. Perform the electronic control unit (ECU) programming.
3.1

Update and confirm the electronic control module (ECM) calibration code.

3.2

Connect the Cummins INSITE™ service tool to the vehicle’s electronic data link.

3.3

Find and note the current calibration code.

NOTE: If you have updated the ECM to the same code on a previous vehicle, Cummins INSITE may have
the new calibration stored.
3.4

Log in to Cummins QuickServe®, and select the ‘DEF Header ECM’ look-up tool. Use the current
code to search for the new calibration code. For detailed instructions, see Cummins Technical Service Bulletin 210187.

3.5

If the current calibration code and the new code are different, install the new calibration code and
continue with the next step. If the current and new code are the same, continue with the next step.

3.6

End the session with Cummins INSITE, and turn the ignition key to the OFF position.

3.7

Turn the ignition key to the ON position, and start the engine.

3.8

Let the engine idle for up to five minutes.

3.9

Confirm the diesel exhaust fluid (DEF) tank level is displaying on the gauge, while monitoring the
fault codes related to the DEF quality.

3.10 Does the DEF level gauge work and does the vehicle idle for five minutes without any DEF quality faults?
YES → Go to step 25, page 9.
NO → Go to step 4.

Page 6

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)
4. Open the hood.

WARNING
Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled.
Use extreme care when removing the cap. A sudden release of pressure from removing the cap prior to
the system cooling can result in a surge of scalding coolant that could cause serious personal injury.
5. To prevent leakage from the DEF tank connections, recover the engine coolant, and store in clean container.
6. If so equipped, remove the DEF tank beauty cover.
7. Transfer enough DEF from the tank to be able to lift the DEF tank off the mounting bracket. Store the removed DEF in a clean container.
IMPORTANT: Wait at least five minutes after shutting down the engine to service the DEF lines. The system
requires time to purge the DEF from the lines.

NOTICE
To separate the DEF fittings, push the line coupling in towards the male connector to move the holding
clip to the unlocked position, then compress the prongs of the holding clip and pull the line off of the
male connector. Failure to properly remove a DEF line can result in damage to a line coupling or DEF port.
8. Remove the DEF lines from the supply and return ports. See Fig. 1, on the next page.
9. Remove the wiring harness connections from the tank header unit. See Fig. 1.
10. Remove the coolant lines from the supply and return ports. See Fig. 1.
11. If any chassis-mounted component is mounted close enough to prevent the tank from sliding off the mounting studs on the frame bracket, then the bracket will need to be removed from the frame.
If removing the tank from mounting studs is not possible, then remove the fasteners that secure the tank
assembly to the frame casting, and remove the assembly from the frame casting. Remove the two capscrews that secure the tank and retaining washers on the mounting studs. See Fig. 1.
NOTE: If the tank is not removed from the mounting studs, the gap between the mounting holes can pinch the
foot of the DEF header, and make it difficult to install.
12. Slide the tank off of the mounting studs.

Page 7

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)

5
4
3

6

2

7

1

11

12

10

8
9

13
14
11/08/2023

1.
2.
3.
4.
5.
6.

DEF Tank
DEF Suction Port
DEF Return Port
Bolts (qty. 6)
Frame Casting
Tank Mounting
Bracket
7. Filler Cap
8. Filler Neck

f490618

9. O-ring
10. Wiring Harness
Connector
11. Coolant Ports
12. Header Unit
13. Tank Retaining
Washer (qty. 2)
14. Capscrew (qty. 2)

Fig. 1, 6-Gallon DEF Tank Mounting Assembly

Page 8

Daimler Truck
North America LLC

Recall Campaign

January 2024
FL974 A-G
(Revised February 2024)

NOTICE
The foot of the header is oriented away from the filler port. It must be ‘maneuvered’ out of the tank.
Applying excessive force to the header during removal or installation may damage it.
13. Remove the existing header unit from the tank.
13.1 Raise the header unit up until it stops (about eight inches).
13.2 Rock the unit away from the filler neck to clear the internal structure. Then, lift the unit out of the tank.
14. Install a new header unit into the tank.
14.1 Position the foot of the unit pointing away from the filler neck, and slide it into the tank.
14.2 Lower the unit until it contacts the inner structure, then carefully rock the top towards the filler neck
working the unit into the tank.
14.3 Lower the unit into position.
14.4 Install the fasteners and tighten 72 lbf·in (813 N·cm).
15. Slide the tank onto the mounting studs.
16. Install the two tank retaining washers on the tank mounting studs.
17. Install the two capscrews onto the mounting studs, securing the tank and retaining washers on the tank
mounting studs. Tighten the capscrews 11 to 18 lbf·ft (15 to 24 N·m).
18. If the tank bracket was removed from the frame casting, install the tank assembly on the frame casting.
Tighten the four tank assembly mounting bolts 112 lbf·ft (152 N·m).
19. Install the coolant supply and return lines to the coolant ports on the tank.
IMPORTANT: To connect the DEF lines, push the line coupling on the male connector of the DEF port. Then,
gently pull back the coupling to engage the holding clip in the locked position.
20. Clean any DEF crystals from the DEF header ports on the tank and the line fittings.
21. Install the DEF supply and return lines to the DEF ports on the back of the tank.
22. Install the wiring harness connections to the tank header unit.
23. Fill the DEF tank with the fluid recovered during the removal process.
24. Fill the cooling system and check for leaks. Perform any bleeding procedures required by the engine supplier. See Group 20 of the applicable Workshop Manual.
25. Clean a spot on the base label (Form WAR259) and attach a recall completion sticker for FL974 (Form
WAR260), indicating this work has been completed.

FL974 B — TBB 10-Gallon Tank Header
1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2. Perform the electronic control unit (ECU) programming.
2.1

Update and confirm the electronic control module (ECM) calibration code.

2.2

Connect the Cummins INSITE™ service tool to the vehicle’s electronic data link.

2.3

Find and note the current calibration code.

NOTE: If you have updated the ECM to the same code on a previous vehicle, Cummins INSITE may have
the new calibration stored.