2021 Freightliner Cascadia

On May 26, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23010) to assess reports of false positive activation of the Automatic Emergency Braking (AEB) system in model year (MY) 2017-2022 Daimler Trucks North America (DTNA) vehicles. The reports alleged that activation of the AEB system occurred while driving with no apparent obstruction in the vehicle's forward path, resulting in sudden vehicle deceleration. DTNA indicated that it received of a total of 315 reports that may relate to the alleged defect in MY 2017-2022 DTNA vehicles. DTNA stated that the vast majority of false positive activation of the subject systems occur in very limited durations and result in a five mile per hour deceleration. ODI considered four AEB systems offered by DTNA: Detroit Assurance 2.0, Detroit Assurance 4.0, Detroit Assurance 5.0, and Wabco OnGuard.  ODI’s analysis shows that of the Detroit Assurance versions, all are failing at similar rates. The OnGuard AEB systems equipped on the same model and model year vehicles have experienced a significantly lower claim rate. To date, ODI has received a total of 32 consumer complaints of inadvertent activation of AEB in MY 2017-2022 DTNA vehicles. In total, ODI reviewed 347 unique (i.e., non-duplicative Vehicle Identification Numbers) reports that may relate to the alleged defect, which include 24 reports involving a crash, 13 reports involving an alleged injury and one report with a fatality. PE23010 has been upgraded to an Engineering Analysis to further assess the scope, frequency, and potential safety related consequences of the inadvertent AEB activations in MY 2017-2022 DTNA vehicles. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

On May 26, 2023, the Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE23010) to assess reports of false positive activation of the Automatic Emergency Braking (AEB) system in model year (MY) 2017-2022 Daimler Trucks North America (DTNA) vehicles. The reports alleged that activation of the AEB system occurred while driving with no apparent obstruction in the vehicle's forward path, resulting in unexpected and sudden vehicle deceleration. ODI sent an information request letter to DTNA on June 15, 2023.In its September 1, 2023, response, DTNA indicated that it received of a total of 315 reports that may relate to the alleged defect in MY 2017-2022 DTNA vehicles. DTNA stated that the vast majority of false positive activation of the subject systems occur for very limited durations and result in a five mile per hour deceleration. ODI considered four AEB systems offered by DTNA: Detroit Assurance 2.0, Detroit Assurance 4.0, Detroit Assurance 5.0, and Wabco OnGuard. ODI’s analysis shows that of the Detroit Assurance versions, all fail at similar rates. The Wabco OnGuard AEB systems equipped on the same model and model year vehicles have experienced a significantly lower claim rate. To date, ODI has received a total of 32 consumer complaints of inadvertent activation of AEB in MY 2017-2022 DTNA vehicles. In total, ODI reviewed 347 unique (i.e., non-duplicative Vehicle Identification Number) reports that may relate to the alleged defect, which include 24 involving a crash, 13 reports involving an alleged injury and one report with a fatality. PE23010 has been upgraded to an Engineering Analysis (EA25006) to further assess the scope, frequency, and nature of the inadvertent AEB activations in MY 2017-2022 Freightliner Cascadia and Western Star 5700 vehicles.In particular, this EA will assess the safety consequences likely to arise in the scenarios during which the AEB inadvertently and unexpectedly activates, such as the speeds and conditions during which the activation occurs. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation to investigate reports of engine electrical wiring harness chafe on the subject vehicles.ODI analysis found thousands of unique harness part numbers, spanning the two generations of vehicle chassis assembled at multiple vehicle assembly plants in two different countries, with multiple sub-models, incorporating over thirty powertrain choices.Each wiring harness could contain several dozen individual wires for power, ground and communication purposes depending on the multitude of equipment options available for custom vehicle configuration. ODI identified three primary areas where a wiring harness bundle may chafe: the air compressor support bracket, the transmission case, or the coolant surge tank. In each case, the root cause was some combination of inadequate design clearance, installation variability and relative motion between the wiring harness and the point of contact, such as from vibration. The chafing could result in a range of consequences from none to various diagnostic fault codes, telltale illumination, driver warning center messages, erratic electrical component operation, difficult or no engine start condition, engine de-rate (power reduction), engine shut down, inoperative transmission gear selection, or an unexpected shift to neutral.These potential consequences vary depending on the specific damaged wire in the harness and the exact failure mode, such as intermittent short circuit to ground or open circuit. Generally, the chafing resulted in a progressive series of driver warnings with high levels of detectability over the course of several days and ignition cycles. Drivers usually heed warnings before an engine shutdown condition occurs and the driver may override an engine shutdown countdown timer using the override switch. If the driver allows the shutdown event to occur, the engine can almost always be immediately restarted. Incident rates for an engine shutdown with no warning or a transmission shift to neutral while driving are both very low. ODI received one complaint (NHTSA ID Number 11366557) from a fleet mechanic, who reported in a subsequent interview that he repaired at least six subject vehicles that experienced the alleged defect condition. However, there have been no new Vehicle Owner Questionnaire complaints received by ODI since opening this investigation, and there are no known crashes, fires or thermal events, or injuries or deaths related to the alleged defect. Accordingly, no safety-related defect trend has been identified. Based on available information, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI report cited in the Closing Resume ODI Report Identification Numbers document, go to NHTSA.gov.

On August 31, 2020, the Office of Defects Investigation (ODI) opened a recall query, RQ20001, to investigate the allegations of water intrusion into the truck cab signal-detect and activation module (SAM cab).The investigation further evaluated the effectiveness of the original recall remedy, and the installation of an updated drip shield as it relates to continual water intrusion resulting in the loss of electrical functions and potential fire.The potential hazard was the increased risk of a crash and injury in certain model year (MY) 2007-2021 Freightliner Cascadia P3 vehicles manufactured by Daimler Trucks North America (DTNA). ODI sent DTNA an information request (IR) letter on September 29, 2020.DTNA's November 20, 2020, IR response detailed how the company had implemented various improvements through recall 09V024 and multiple technical service bulletins (TSBs) to mitigate water intrusion.The effectiveness of new windshield seals and revisions to the drip shield is evident by the downward trend in claims rate from an average high of 7.64% in the beginning product life of Cascadia P3 (MYs 2007-2009), to 1.79% average for MYs 2011-2018, and down to 0.49% towards the end of the Cascadia P3 production.Moreover, the data shows that most failures occurred within the first three years of service with a significant downward trend thereafter. In view of the current overall low failure rate, the nature of early-life failure, and failure rate trending downward since model year 2017, this Recall Query (RQ) is closed.  The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

While vehicle approached a hazard blocking the roadway the forward collision and automatic braking feature did not engage; apparently due to the vehicle sensors not recognizing the hazard. The object in the roadway was a 53 ft van trailer that was laid on it's side with the translucent roof facing the approaching vehicle.

NHTSA ID

11569193

Incident

Dec 14, 2023

When driving, there is a constant and very strong vibration throughout the entirety of the truck. This makes it difficult to steer and drive in a safe manner. I've replaced any parts that might be associated with this malfunction with brand new parts at the advice of professional mechanics (cost over $30,000) and it was to no avail. The truck is still malfunctioning and I have been left unable to work or barely working for 14 months. The vibration has caused many health concerns, like headaches, nausea, and stomach ulcers. I went to over 10 dealers and there has been no solutions that have worked.

NHTSA ID

11561665

Incident

Oct 10, 2022

My Emplyoer has not fixed anything on the truck, the truck shouldn’t be operating, doesn’t meet DOT Regulations, I was told not to go into any scales or weigh stations, loses air and the air doesn’t build back up properly, I lost all air in my breaks while driving on the road

NHTSA ID

11530297

Incident

Jun 1, 2023

I'd like to report the automatic braking device on our company semi tractor. I work for a large mega carrier hauling all types of freight, with triples and doubles combination trailers. We operate with Freightliners, Kenworths, and Internationals. The tractor tractor I use is a 2021 Freightliner equipped with a safety feature, an automatic braking system to avoid collisions for stopped or slowed traffic ahead. The issue is, it randomly brakes with no obstructions ahead. I've seen reports that you guys are looking into this. And I'm also informing you that our trucks deal with this issue as well. There's no defect warnings on the device's monitor system. No previous accidents that would cause issues to the device to have faulty sensor. The problem with the system, it sees a shadow on the road and it thinks theres a stopped vehicle, forcing the truck to hard apply the brakes. This can be extremely dangerous on inclement weather, more so on icy conditions. Few weeks ago, I traveled through the same part of the toll road like I always do, I know this spot activates the brakes 70-85% of the time during the night. That night, my trailers ABS light was on, when I approached the bad spot, all my brakes activated and almost caused my truck to jack-knife, lost full control but didn't crash, nor was anyone near me. But it would've been a different outcome if it was bad weather. When I approach this area, I always turn on my high beams to try to eliminate the shadow on the road. Where this happens: Indiana Toll Road 80-90, Elkhart IN, West bound lanes, right before exit 92. The overpass that causes this shadow is Johnson Street. You can see on Google street maps, where other trucks have had automatic braking activated, from seeing tire marks on the road. The lights around create that shadow at night. I would just like to inform you guys of my experiences. I have also reached out to INDOT about the issue, not sure if they looked into it. Reporting before a crash could happen.

NHTSA ID

11529649

Incident

Jun 28, 2023

The contact owns a 2021 Freightliner Cascadia. The contact stated while driving 65 MPH with the cruise control activated, the brakes applied independently. The contact took the vehicle to the local dealer, where it was diagnosed with needing the calibration of the radar. The vehicle was repaired but experienced the failure within a week. The contact took the vehicle back to the local dealer, where it was diagnosed with needing the radar to be replaced. The vehicle was repaired but continued to experience the same failure within a month. The contact took the vehicle back a third time to the local dealer, where it was diagnosed with needing the recalibration of the radar. The vehicle was repaired but continued to experience the failure intermittently. The contact called the local dealer and made them aware of the failure. The vehicle was not repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 215,000.

NHTSA ID

11524581

Incident

Apr 20, 2022

Mileage

215,000 mi

This complaint is being filed in addition to my previous complaint which is complaint #1147128511471285. Both left and right vehicle airbag suspension height regulators were just replace a month ago, and once again, the right side airbag ride height regulator has blown apart, causing my semi truck to lean heavily to the right side, and wear out my right front steer tire exceedingly fast. And, the radar braking system erratically slams the brakes on at random times, which could cause a catastrophic accident. Imagine hauling an 80,000 lb. load, and the truck just decides to slam on the brakes, in a corner, in the rain, or in the snow. You’re riding a very thin line between life and death. Freightliner will now be sued for negligence, embezzlement, fraud, and loss of use of my truck. My truck just spent 40 days at the Freightliner Dealership for several Factory Safety Recalls, and they just replaced both airbag ride height control vale’s, because they both failed. If this isn’t a clear cut case of the Federal Lemon Law, nothing is.

NHTSA ID

11485349

Incident

Sep 19, 2022

TIRE SIZE: 275/80 R22.5 MICHELIN ENERGY LINE Z Component that failed is drivers side steer front tire. The tire blew out and resulted in loss of vehicle control. This failure DID cause an accident putting others safety at risk. Both Freightliner Corp. and Michelin Tire Co. are aware of this failure. No one has inspected the tire. I DO NOT have the tire in my possession yet. There are/were no warning, messages or symptoms of this problem prior to. This truck had a right side tire failure at the decoupling groove on May 11, 2022. The tire was replaced at that time with a new tire tire. This truck returned to Toledo Ohio to our terminal. The 4X4X4 air fairings were then removed at the request of DTNA. On 8-5-22 with 52,742 miles on the tire, it blew out resulting in an accident.

NHTSA ID

11477923

Incident

Aug 5, 2022

TIRE SIZE: 275/80 R22.5 MICHELIN ENERGY LINE Z Component that failed is passenger side steer front tire. The outside edge decoupling groove/sidewall failed. Risks include potential tire blow resulting in loss of vehicle control. This failure could cause an accident putting others safety at risk. Both Freightliner Corp. and Michelin Tire Co. are aware of this failure. No one has inspected the tire. I have the tire in my possession. There are/were no warning, messages or symptoms of this problem prior to. Michelin Tire Co. sent us 2 new tires and requested we remove the air fairing to see if this could resolve the problem. At the time we proceeded with this request the truck had 315,805 miles on it. On 6-20-22 Michelin Tire Co. supplied Freightliner Corp. with a tech bulletin regarding the decoupling groove failure. At 455,485 miles this tire was showing signs of decoupling failure. This failure appeared to be within the guide lines of the tech bulletin. At 465,523 miles the tire showed excessive decoupling groove failure in multiple spots. Mileage on tire at the time of failure was 149,718 miles.

NHTSA ID

11476312

Incident

Jul 5, 2022

Truck Equipment Manufacturer upfit guide for Detroit Assurance Forward Radar Relocation and Adjustment

Revised Technical Service Bulletin for ABS Wheel Speed Fault Code Correction for MBSP Equipped Vehicles. Updated frequently asked questions.

CX Advocate for Utility Lamp water intrusion

Revised Technical Service Bulletin for DT12 OVX Transmission Refresh

CX Advocate for P4 Side Guard Assist On/Off Menus and Trailer Functionality (TSB-54-381-FTL)

Revised Field Service campaign for Cascadia Axle Conversion: Adaptive Tandem (AT) 6x4 to New Final Drive (NFD)