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Old 05-02-2024, 08:33 AM   #1
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Still fighting with Freightliner and Jayco...

OK, it has been a while since I have posted on here. Some may remember the issues from the beginning.
2022 37K S2RV chassis.
about 2K miles it had coolant leaks, ABS issues, Transmission leak and electrical issues in the coach.
These were fixed but it did cost me out of pocket a few hundred dollars.

Fast forward, The coach now has 12k miles
Each trip I have taken I get a Check Engine Light, multiple engine codes, coach derates and slows to 35mph. It has been back to Freightliner numerous times, it has been to Cummins a few times even put on the chassis dyno.
Fuel Rail Sensors have been replaced, on the 4th set of fuel filters.
Last weekend while heading to a race pulling my trailer, check engine light came on again, went into limp mode and barely made it to the track. No codes this time. Raced all day and left to come home. Coach seemed to run fine but the check engine light was on the whole way.
Yesterday took it back to Freightliner, on the way there it went into limp mode again, they called and said it needed fuel filters. I argued the point that these had less than 2K miles on them and had already been changed 4x and the issue keep happening. They are telling me they do not see any other issue.

So after 10 trips to Freightliner and 2 to Cummins we are still having the same issues of check engine light, fuel rail sensors, low power etc. I am out over 10K in chassis repairs, including a few tow bills, rental cars, loss of work and repairs that I have had to pay for that Freightliner has turned a blind eye to. Not to mention Jayco won't even call me back about the 4K in repairs to the water system, trim falling off, mud flaps falling off, paint issues that had to be repaired.

Just more of a rant but has anyone else had the check engine light low power issue that could not be resolved?
Very frustrating as I do not trust this coach anymore. 12 out of the 15 long distance trips has either left me stranded or sitting in the parking lot at Freightliner with a race trailer in tow.
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Old 05-02-2024, 09:24 AM   #2
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aqharoper, I apologize in advance for the stupid / redundant questions I am about to ask!
Have any of the removed filters been drained and cut apart to determine if they were the root cause of the issues you are having?
Has a separate supply fuel line been run to see if that is the issue? (I have seen hoses separate on the inside and cause flow restrictions.)

Any of the fuel pumps been replaced?
Any possibility of a tank vent being a problem?
Sounds like they are focusing on a fuel supply issue. Is there a way to mount a sensor on the fuel supply line before the pump? Even if you externally plumbed in a MAP sensor might tell you something?


Sorry you are having all of these issues!!
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Old 05-02-2024, 09:35 AM   #3
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Are you running bio-diesel? We had multiple issues with clogged filters a few years back because of it.
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Old 05-02-2024, 10:39 AM   #4
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aqharoper, I apologize in advance for the stupid / redundant questions I am about to ask!
Have any of the removed filters been drained and cut apart to determine if they were the root cause of the issues you are having?
Has a separate supply fuel line been run to see if that is the issue? (I have seen hoses separate on the inside and cause flow restrictions.)

Any of the fuel pumps been replaced?
Any possibility of a tank vent being a problem?
Sounds like they are focusing on a fuel supply issue. Is there a way to mount a sensor on the fuel supply line before the pump? Even if you externally plumbed in a MAP sensor might tell you something?


Sorry you are having all of these issues!!
Rick
Filters have been cut apart. Did not see any signs of clogs etc. They have been changed 4x (3x by Freightliner 1X by myself) in 12K miles. I cannot see that as an issue. Fuel samples were taken from tank. Completely clear. It seems to keep suffering from low pressure. I have asked them to check lines and the pump outlet pressure. They just keep changing filters and charging me for that and diagnostic fees which I feel I shouldn't be paying for considering this has been going on for 14 months.

No Biodiesel where I live. Just straight diesel and I usually only buy from Pilot, Flying J or Loves. MH is stored in my race shop so no chance of someone putting something in the tank.
So right now Freightliner has me on the hook for another filter change and diagnostic fee.
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Old 05-02-2024, 10:46 AM   #5
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Pilot and Flying J do sell BIO B-20 in 27 states, Loves does to. I quit using them and always went to Shell because of it.

This is from a 2020 article...

For example, in mid-May, Pilot and Flying J were selling biodiesel blends at nearly 300 locations in 27 states. Almost all of those locations were selling B20, meaning the fuel was 20% biodiesel and 80% petroleum diesel.
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Old 05-02-2024, 11:29 AM   #6
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Pilot and Flying J do sell BIO B-20 in 27 states, Loves does to. I quit using them and always went to Shell because of it.

This is from a 2020 article...

For example, in mid-May, Pilot and Flying J were selling biodiesel blends at nearly 300 locations in 27 states. Almost all of those locations were selling B20, meaning the fuel was 20% biodiesel and 80% petroleum diesel.
I saw that article and thought it was mostly western states??
I am in Georgia and have yet to see any Bio diesel around here but will check to make sure.
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Old 05-02-2024, 12:18 PM   #7
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First I have become aware of biodiesel. Is an 80-20 biodiesel blend really bad for this engine such that I should avoid it? I'm in my 3rd year of ownership, usually fuel up at Loves. Should I not? Appreciate the opinion of those in the know please.
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Old 05-02-2024, 12:32 PM   #8
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keep up with the filters and there is nothing wrong with B20. Just don't let it sit for months at a time.
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Old 05-02-2024, 01:48 PM   #9
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The Cummins 6.7 ISB is approved for the use of B20 Bio fuel.
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Old 05-02-2024, 02:41 PM   #10
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I don't know if this is any help or not, my father in-law had a similar issue about 6 years ago. He went through a lot of what you are describing. His issue turned out to be when the fuel tank was installed it pinched the fuel line. The only way it was found was because they decided to change out the whole tank for some reason. The pinch was not in an area it could be seen by inspection. I would ask him but he has since passed away. I have no idea if this helps but it sounds so familiar, i wanted to share what his issue was. Good luck


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Old 05-03-2024, 09:32 AM   #11
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So after my call with Freightliner yesterday they stated the only issue was the filters. I told them to drive the rig a long distance before I come pick it up. Interesting it did the same for them as I have been telling them for 1yr now. First time I have had a tech drive it or ride in it. Now they are stating the sensor in the water separator is bad. I cannot see this causing a low fuel pressure problem and going into limp mode. Still fighting with Freightliner FCCC about me having to pay out of pocket.
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Old 05-03-2024, 09:48 AM   #12
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Thanks for the update. At least they have seen your coach misbehave. You should not have to fund their parts cannon. I would think the sensor in the water separator would have thrown a code.
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Old 05-03-2024, 10:09 AM   #13
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Originally Posted by aqharoper View Post
So after my call with Freightliner yesterday they stated the only issue was the filters. I told them to drive the rig a long distance before I come pick it up. Interesting it did the same for them as I have been telling them for 1yr now. First time I have had a tech drive it or ride in it. Now they are stating the sensor in the water separator is bad. I cannot see this causing a low fuel pressure problem and going into limp mode. Still fighting with Freightliner FCCC about me having to pay out of pocket.
This reminds me of years ago when it was common to remove the fuel line at the engine and determine the fuel flow rate (for similar issues). If the fuel flow rate was low then change\check the filters, followed by checking all the fuel lines, then replacing the fuel pump. Things are a bit different now but it would seem to me that a new style test based on what was done years ago could still occur. ~CA
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Old 05-03-2024, 10:30 AM   #14
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I would also suspect a pinched fuel line, Jayco runs a lot of wiring and lines across the top of the tank and if your water tank is above the fuel tank like mine is, having a full water tank could sag the compartment down and pinch off a line. I had this issue with a propane line they ran over the frame and across the top of the tank. Here is a couple pics, one is how the fuel tank sets in a bare frame and the other is a shot of the top of the tank with the compartment shell sagging down on top of the lines and hoses.
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Old 05-04-2024, 04:14 PM   #15
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Very sorry to hear of your Freightliner Chassis issues. What was the cause of the transmission leak and was that covered? I just notice I have a transmission leak with 12k miles on my 2022 37M.

You mentioned you are out 10k, but I thought these had a 3-5 years warranty on the engine/chassis.
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Old 05-06-2024, 02:44 PM   #16
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Very sorry to hear of your Freightliner Chassis issues. What was the cause of the transmission leak and was that covered? I just notice I have a transmission leak with 12k miles on my 2022 37M.

You mentioned you are out 10k, but I thought these had a 3-5 years warranty on the engine/chassis.
The transmission leak was at 2K, they added 3 qts if fluid and told me it was a maintenance issue and no leak. Charged me $300 for the fluid. Later I found a cooler line loose.
I have had problems since day 1 with this coach. Every time we go racing it either leaves us stranded or limps to Freightliner. Freightliner cares nothing about helping. Everytime it goes there its between $300 and $1K. I have talked to FCCC with not much help. This does not include the repairs out of pocket oh JAYCO's side. Coach is just at 15months old.
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Old 05-06-2024, 03:46 PM   #17
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The transmission leak was at 2K, they added 3 qts if fluid and told me it was a maintenance issue and no leak. Charged me $300 for the fluid. Later I found a cooler line loose.
I have had problems since day 1 with this coach. Every time we go racing it either leaves us stranded or limps to Freightliner. Freightliner cares nothing about helping. Everytime it goes there its between $300 and $1K. I have talked to FCCC with not much help. This does not include the repairs out of pocket oh JAYCO's side. Coach is just at 15months old.
Might be time to try a new place to get it serviced... I just dropped mine off a few hours ago at Transwest, they are an authorized Freightliner service station. Hopefully, they will figure it out and not send me on my way to tell me it is normal. An engine/transmission leak under 15k miles is certainly not normal. I have box trucks with the same engine and transmission that don't leak after 200k miles!
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Old 05-06-2024, 06:44 PM   #18
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Might be time to try a new place to get it serviced... I just dropped mine off a few hours ago at Transwest, they are an authorized Freightliner service station. Hopefully, they will figure it out and not send me on my way to tell me it is normal. An engine/transmission leak under 15k miles is certainly not normal. I have box trucks with the same engine and transmission that don't leak after 200k miles!

Where is your leak? I just had to replace my transmission cooler due to 2 cracks, one was leaking coolant and the other was leaking trans fluid. First pic is the cracked weld leaking coolant and the second there was a crack around the threaded bung where its welded into the housing.
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Old 05-06-2024, 08:24 PM   #19
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Where is your leak? I just had to replace my transmission cooler due to 2 cracks, one was leaking coolant and the other was leaking trans fluid. First pic is the cracked weld leaking coolant and the second there was a crack around the threaded bung where its welded into the housing.
Really fast turnaround at the Freightliner dealer. Dropped it off at 1 pm with no appointment and by 5 pm, they diagnosed it as the control module gasket. It is the gasket for the large pan on the bottom of the transmission. They could start it tomorrow BUTTTTTTTTTTT, NIRV never registered my rv with Freightliner. I had to find the bill of sale and they have to see if their financing department can take of it before they will start the work! So pissed at NIRV, just adding insult to injury at this point. Sorry for the rant.

I found a video to the control module removal. I had no idea that the control module was the entire bottom end. I figured it was some small gasket. I could do this at home, but it would be a pain in the butt as all the transmission oil needs to be drained and the pan is heavy. After looking at this gasket, it does seem plausible that this is where the leak was coming from. Not sure if it was pinched or what...

I am going to have them install the Roadmaster Exact Center stabilizer that I had already purchased while it is in the shop. I just have not had the time to take care of that and figure they will get it set correctly faster than I could.
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Old 05-08-2024, 01:51 PM   #20
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I had a very similar problem and it turned out to be as simple as a faulty fuel tank cap.
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