10-1539 – Axle May Be Installed Backwards – 2022 Forest River Flagstaff & 2022-2023 Rockwood Tent Campers

August 1, 2022 NHTSA CAMPAIGN NUMBER: 22V558000

Axle May Be Installed Backwards

A loss of brake function increases the risk of a crash.

 

NHTSA Campaign Number: 22V558

Manufacturer Forest River, Inc.

Components SUSPENSION, EQUIPMENT

Potential Number of Units Affected 244

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2022 Flagstaff and 2022-2023 Rockwood tent campers. The axle may be installed backwards, which can reduce brake function.

 

Remedy

Dealers will inspect and properly install the axle if necessary, free of charge. Owner notification letters were mailed August 24, 2022. Owners may contact Forest River Customer Service at 1-574-642-8943. Forest River’s number for this recall is 10-1539.

 

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.nhtsa.gov.

 

---

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 2022 Flagstaff and 2022 – 2023 Rockwood Tent Camper 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 axle may be installed backwards on certain single axle tent campers.

 

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

A vehicle without proper braking may increase the risk of a crash.

 

WHAT IS FOREST RIVER AND OUR DEALERSHIPS GOING TO DO?

Forest River is notifying dealerships of the recall. You may have the recall corrected at any Forest River dealership. An authorized Forest River dealer or service center will need to perform the remedy. The axle(s) will be inspected for proper installation, if incorrect installation is found, the axles will be installed correctly per the remedy instructions. 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 1.5 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:

Rockwood & Flagstaff
Forest River, Inc.
Attn: WARRANTY MANAGER
201 W Elm St
Millersburg, IN 46543

 

---

RECALL 22V558, 2022-415 REMEDY INSTRUCTIONS

Make(s): ROCKWOOD & FLAGSTAFF Model(s): SEE BELOW Model Year(s): SEE BELOW	Repair Code: RC-006-03-00-004222 Allotted Time: 1.50 HRS. Inspection Code: RC-006-05-00-004221 Allotted Time: .10 HRS.
Concern: The axle may be installed backwards on certain single axle tent campers.	Photo(s) Required: YES, BEFORE & AFTER Prior Authorization Required: YES 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.

NOTE: INSPECTION AND REMEDY CODES CANNOT BE CLAIMED TOGETHER FOR THIS CAMPAIGN.

CERTAIN: 2022 – FLAGSTAFF FS176LTD & FS206LTD
CERTAIN: 2022 – 2023 – ROCKWOOD FM1640LTD & FM1940LTD

INSPECTION:

STEP 1: LOCATE THE AXLE SPRING ON THE FRONT SIDE OF THE AXLE (PORTION OF AXLE TOWARDS THE FRONT/HITCH) (FIGURE 1);

STEP 2: IF THERE IS A STEEL BAND (FIGURE 2) ON THE FORWARD SIDE OF THE SPRING PACK, THE AXLE IS INSTALLED CORRECTLY;

STEP 3: IF THE STEEL BAND (FIGURE 2) IS ON THE REARWARD SIDE OF SPRING PACK, THE AXLE IS INSTALLED INCORRECTLY AND REQUIRES REMEDY. MOVE ON TO “REMEDY”;

STEP 4: CLAIM REPAIR CODE FOR INSPECTION, ONLY.

 

REMEDY:

STEP 1: USE A FLOOR JACK TO RAISE THE WHEELS OFF THE GROUND BY JACKING FROM THE MAIN BEAM;

STEP 2: PLACE JACK STANDS IN FRONT AND BEHIND THE TIRES

– 2 – JACK STANDS FOR OFF DOOR SIDE (PLACE UNDER MAIN BEAM)

– 2 – JACK STANDS FOR DOOR SIDE (PLACE UNDER MAIN BEAM)

STEP 3: LOCATE AND CUT THE BRAKE WIRES (2). ENSURE YOU LEAVE ENOUGH WIRING TO HOOK BACK UP;

STEP 4: LOCATE THE BOLTS;

– LOCATE FOUR SHACKLE BOLTS ATTACHING THE SPRING PACK TO THE CHASSIS;

– LOCATE THE TWO SHACKLE BOLTS ATTACHING THE STEEL SHACKLES TO THE AXLE;

– USE A WRENCH TO HOLD THE SHACKLE BOLT HEAD IN PLACE – USE A WRENCH TO REMOVE THE SHACKLE NUT(S);

– THE SHACKLE BOLTS HAVE SERRATED SHANKS AND APPLYING TORQUE TO THE BOLT HEAD MAY CAUSE THE SHANK SERRATION FAILURE. IF THIS HAPPENS, YOUR DEALERSHIP MAY BE RESPONSIBLE FOR THE COST OF REPLACING THE SHACKLE BOLT(S).

STEP 5: ENSURE TO LEAVE ENOUGH SPACE BETWEEN THE JACK STANDS AND AXLE THAT YOU CAN GET THE AXLE OUT WITHOUT INTERFERENCE;

– ROTATE THE AXLE 180°, ENSURING STEEL BAND IS ON THE FRONT SIDE OF THE VEHICLE NOW;

– MANOUVER AXLE UNDER VEHICLE AND LIFT TO INSERT THE FRONT SPRING PACK EYELET INTO THE FRONT AXLE HANGERS ON THE DOOR SIDE AND OFF DOOR SIDE;

– SEAT SHACKLE BOLTS WITH A HAMMER UNTIL BOLT HEAD IS FLUSH TO HANGER(S);

– ATTACH SHACKLE PLATES TO REAR OF THE AXLE EYELET ON THE DOOR SIDE AND OFF DOOR SIDE;

– ROTATE AXLE UP AND SEAT SHACKLE PLATE(S) TO REAR AXLE HANGERS ON DOOR SIDE AND OFF DOOR SIDE. SEATING SHACKLE BOLTS WITH A HAMMER;

STEP 6: USE A BOX WRENCH AND PLACE ON THE BOLT HEAD AS A BACKER WRENCH AND HOLD FIRMLY WHILE YOU TIGHTEN THE NUT AGAINST THE AXLE HANGERS AND SHACKLE PLATES;

– TIGHTEN UNTIL A MINIMUM OF THREE (3) SHACKLE BOLT THREADS SHOW PAST THE NUT AND THE NUT IS SEATED.

– FAILURE TO USE A WRENCH MAY STRIP THE SHACKLE BOLT. IF THIS HAPPENS, YOUR DEALERSHIP MAY BE RESPONSIBLE FOR THE COST OF REPLACING THE SHACKLE BOLT(S).

STEP 7: RECONNECT BRAKE WIRES.

• ON THE OFF DOOR SIDE OF THE TRAILER. ROUT NEW WIRING TO THE BRAKES FROM THE DOOR SIDE IF THAT WAS WHERE THE BRAKE WIRES TERMINATED FROM THE JUNCTION BOX.
• IF THE BRAKE WIRES WHERE ROUTED ON THE OFF DOOR SIDE, DO NOT ROUT NEW WIRING, SIMPLY REMOVED EXCESS WIRING FROM THE OUTSIDE OF THE AXLE TUBE AND DISCARD.
• TEST BRAKE WIRES TO ENSURE BRAKES WORK.

 

IF THE SPRING BAND IS ON THE FORWARD SIDE (HITCH SIDE) OF THE AXLE – THE AXLE IS INSTALLED CORRECTLY.

IF THE SPRING BAND IS ON THE REARWARD SIDE (BUMPER SIDE) OF THE AXLE – THE AXLE IS INSTALLED INCORRECTLY

 

---

Chronology :

On July 27, 2022, this concern was discovered by the manufacturing plant. The same day, The manufacturing plant identified the issue when a personnel change was made for installation of the axle(s).

On July29, 2022, Forest Rivers Corporate Recall Committee voted to recall.

On August 4, 2022 US recall was amended due to a clerical error in the Model Years for Rockwood Tent Campers. Originally listed only 2022 models and there is a single 2023 model

 

---

3 Affected Products

Vehicles

MAKE	MODEL	YEAR
FOREST RIVER	FLAGSTAFF	2022
FOREST RIVER	ROCKWOOD	2022-2023

 

---

9 Associated Documents

Defect Notice 573 Report

RCLRPT-22V558-8765.PDF 213.855KB

 

---

Recall 573 Report – 8/4/2022

RCLRPT-22V558-6159.PDF 214.174KB

 

---

Recall Acknowledgement

RCAK-22V558-1735.pdf 645.806KB

 

---

Remedy Instructions and TSB

RCRIT-22V558-7061.pdf 264.663KB

 

---

Manufacturer Notices(to Dealers,etc)

RCMN-22V558-1008.pdf 204.461KB

 

---

ISSUED Owner Notification Letter(Part 577)

RCONL-22V558-0296.pdf 174.32KB

 

---

Recall Quarterly Report #1, 2022-3

RCLQRT-22V558-9869.PDF 211.131KB

 

---

Recall Quarterly Report #2, 2022-4

RCLQRT-22V558-8081.PDF 211.232KB

 

---

Recall Quarterly Report #3, 2023-1

RCLQRT-22V558-8327.PDF 211.312KB

 

---

 

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V558&docType=RCL

 

---

 

 

---