Trailer Brakes May Not Activate – 2020-2022 Coachmen Catalina, & 2021-2022 Forest River Aurora Travel Trailers

July 6, 2022 NHTSA CAMPAIGN NUMBER: 22V477000

Trailer Brakes May Not Activate

Trailer brakes that fail to activate can increase the risk of a crash.

 

NHTSA Campaign Number: 22V477

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 12,141

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2020-2022 Coachmen Catalina, and 2021-2022 Forest River Aurora travel trailers. The breakaway switch may be incorrectly wired to the battery disconnect, which can prevent the trailer brakes from activating as intended.

 

Remedy

Dealers will inspect and re-wire the breakaway switch, as necessary, free of charge. Owner notification letters were mailed August 2, 2022. Owners may contact Forest River customer service at 1-574-825-6241. Forest River’s number for this recall is 51-1529.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

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RECALL 22V477, 2022-358 REMEDY INSTRUCTIONS

Make(s): CATALINA & AURORA Model(s): SEE BELOW Model Year(s): 2020, 2021 & 2022	Repair Code: RC-003-22-00-004205 Allotted Time: .30 HRS. Inspection Code: RC-003-05-00-004204 Allotted Time: .10 HRS
Concern: THE BATTERY/HOUSE AND THE BREAKAWAY WIRING IS INCORRECT ON THE BATTERY DISCONNECT.	Photo(s) Required: YES Prior Authorization Required: NO Part(s) Kit Number: N/A Part(s) Return: N/A

 

Disconnect the vehicles’ battery Positive and Negative, disconnect any House battery(s) Positive and Negative, if equipped with a generator ensure it is off and lastly, ensure the vehicle is disconnected from shore power. Block any tires/wheels to prevent the vehicle from rolling. Failure to do so may result in electrocution, fire or other personal injury, property damage and/or death.

 

CERTAIN 2020 THROUGH 2022 CATALINA AND AURORA TRAVEL TRAILER RECREATIONAL VEHICLES.

STEP 1: LOCATE AND REMOVE SCREWS HOLDING THE BATTERY DISCONNECT FROM THE FRAME (FIG. 1);

STEP 2: CUT AN ACCESS HOLE ROUGHLY 12” X 12” DIRECTLY BEHIND THE FRONT CROSS MEMBER AND BATTERY DISCONNECT. SET 12” X 12” UNDERBELLY ASIDE FOR LATER USE. THIS WILL GIVE YOU ACCESS TO THE JUNCTION BOX AND AUTO-RESET MINI BREAKERS (FIG. 2);

STEP 3: LOCATE THE MINI-BREAKER ON THE FAR RIGHT WITH THE SOLID BLACK WIRE CONNECTED TO THE TOP STUD OF THE MINI-BREAKER. LOOSEN AND REMOVE NUT FROM THE MINI-BREAKER STUD AND PULL THE BLACK WIRE OFF THE STUD OF THE MINI-BREAKER;

STEP 4: LOCATE THE CRIMPED ON EYELET ON THE BLACK WIRE, SNIP OFF THE EYELET. STRIP THE BLACK WIRE AND CRIMP ON A 3/8” EYELET. (EYELET SHALL BE OF THE CORRECT SIZE TO FIT THE BATTERY DISCONNECT LUG);

STEP 5: LOOSEN AND REMOVE THE NUT FROM STUD ON THE BATTERY DISCONNECT THAT IS ASSOCIATED WITH THE CONSTANT POWER. CONNECT THE BLACK WIRE FROM THE BREAKAWAY SWITCH TO THE STUD CONNECTED DIRECTLY TO THE BATTERY (FIG. 3);

STEP 6: TIGHTEN NUT DOWN ONTO THE STUD;

STEP 7: REATTACH THE BATTERY DISCONNECT TO THE FRONT CROSS MEMBER. USE THE SAME FOUR (4) HOLES TO REMOUNT THE DISCONNECT. TAKE GREAT CARE TO NOT SNAP OR STRIP THE SCREWS.
TAKE CARE TO NOT OVER TIGHTEN THE BATTERY DISCONNECT EXCESSIVE TORQUE MAY RESULT IN A BROKEN BATTERY DISCONNECT HOUSING.

NOTE: BREAKAGE AS A RESULT OF REINSTALLING THE BATTERY DISCONNECT IS NOT COVERED UNDER THIS RECALL. YOUR DEALERSHIP WILL BE RESPONSIBLE FOR REPLACING THE BATTERY DISCONNECT AT NO CHARGE TO THE OWNER. THIS PART MAY BE ORDERED FROM CATALINA SEPARATELY, AS/IF NEEDED.

STEP 8: TEST CIRCUIT WITH DISCONNECT IN THE “OFF” POSITION TO ENSURE IT IS IN WORKING ORDER.

STEP 9: USE BLACK TAPE SUCH AS GORILLA TAPE TO SECURE THE 12” X 12” UNDERBELLY PANEL BACK TO THE VEHICLE. ENSURE THE PATCH IS PRESENTABLE TO THE CUSTOMER. THIS WILL ALSO HELP IF IN THE FUTURE THE CUSTOMER OR A DEALER NEEDS TO ACCESS THE CONNECTIONS FOR THE 7 WAY CORD.

 

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This notice is sent to you in accordance with the requirements Motor Vehicle Safety Act. This notice is also sent in accordance with the requirements of the United States’ National Traffic and Motor Vehicle Safety Act. Forest River has decided that a defect, which relates to the motor vehicle safety, exists in certain 2020 – 2022 Coachmen Catalina and 2021 – 2022 Forest River Aurora travel trailer recreational vehicles. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.

 

WHAT IS THE DEFECT/NONCOMPLIANCE?

The breakaway switch wire was connected to a mini-breaker that was connected to the auxiliary side of the battery disconnect. By the breakaway switch being wired to the auxiliary side of the battery disconnect, it is not supplying constant power to the switch, therefore, the switch may not engage when needed and consequently not allow the trailer brakes to activate.

 

EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.

If battery disconnect is in the “off” position, the breakaway switch will not engage when needed, the trailer brakes will not activate which may lead to a crash.

 

WHAT IS FOREST RIVER AND OUR DEALERSHIPS GOING TO DO?

Forest River is notifying dealerships of the recall. An authorized Forest River Dealer or Service Center will need to perform the remedy, which will include inspecting the wiring to the breakaway switch rewire if needed so that the breakaway switch will activate properly. It is preferable if you have your selling dealership perform the remedy. Forest River completely covers your cost for the remedy; you will not receive any bill of sale for anything covered under the above recall number.

 

WHAT SHOULD YOU DO?

Please contact your dealer immediately and request a service appointment to schedule the free remedy. The vehicle Owner is responsible for arranging to have the work completed. Please state you have been notified by Forest River of having a recall in process for your vehicle and provide the recall number for the dealership. It is also helpful to the dealership to have a copy of this letter when you take your vehicle in for the recall remedy. You may also visit www.forestriverinc.com for dealer locations.

 

HOW LONG WILL THE REMEDY PROCESS TAKE?

The estimated time of repair is .30 hours. However, the dealership may need to keep your vehicle or schedule an appointment with you for a later date to fit into their regular service schedule.

 

WHAT IF YOU HAVE PREVIOUSLY PAID FOR REPAIRS TO YOUR VEHICLE FOR THIS PARTICULAR CONDITION?

If you have already paid for a repair that is within the scope of this defect under recall, you still need to have this recall inspected and/or performed to ensure the correct parts and procedures were utilized. Additionally, you may be eligible for a refund of previously paid repairs. Refunds will only be provided for within the scope of this defect under recall.

Please send the service invoice to the following address:

Catalina & Aurora
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury, IN 46540

 

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Chronology :

On June 24, 2022, during a routine Codes & Standards Audit, it was discovered that the breakaway switch was incorrectly wired. Forest Rivers Office of Corporate Compliance was notified by the manufacturing plant of the issue and began to determine the vehicle scope.

 

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5 Affected Products

Vehicles

MAKE	MODEL	YEAR
COACHMEN	CATALINA	2020-2022
FOREST RIVER	AURORA	2021-2022

 

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8 Associated Documents

Recall 573 Report

RCLRPT-22V477-1670.PDF 214.852KB

 

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Recall Acknowledgement

RCAK-22V477-8312.pdf 645.865KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V477-8373.pdf 173.635KB

 

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Remedy Instructions and TSB

RCRIT-22V477-9239.pdf 210.157KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-22V477-6475.pdf 203.655KB

 

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V477-7639.PDF 211.128KB

 

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V477-9093.PDF 211.237KB

 

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V477-5342.PDF 211.319KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V477&docType=RCL

 

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