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October 7, 2022 NHTSA CAMPAIGN NUMBER: 22V748000
Extended Brake Pedal May Contact Dash Panel
Brake failure can increase the risk of a crash.
NHTSA Campaign Number: 22V748
Manufacturer Newmar Corporation
Components SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected 32
Summary
Newmar Corporation (Newmar) is recalling certain 2023 Dutch Star motorhomes. The adjustable brake pedal may come into contact with the dash panel, resulting in unintentional brake engagement, which can cause the brakes to overheat and fail.
Remedy
Dealers will trim the dash panel to add more clearance at the brake pedal and dash panel, free of charge. Owner notification letters were mailed on November 1, 2022. Owners may contact Newmar’s customer service at 1-800-731-8300.
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.
RSB 590
November 01, 2022
NHTSA #22V 748
TC #2022-569
RECALL SERVICE BULLETIN
AFFECTED MODELS
2023 :: Dutch Star
DESCRIPTION
The dash interferes with full extension of the brake pedal assembly.
ISSUE
Newmar Corporation has decided that a defect, which relates to motor vehicle safety, exists in specific motorhomes built on Freightliner and Spartan Chassis.
On certain Newmar motorhomes, when the adjustable brake pedal is fully extended towards the driver, it may contact the dash panel. This can cause the brakes to partially be applied. Continuing to drive with the brakes partially applied may cause the brakes to overheat and cause a brake failure.
UNITS AFFECTED
Please refer to the attached population list for affected units and VINs.
CORRECTIVE ACTION
Follow the attached work instructions to trim the plastic dash panel.
PARTS NEEDED
Item Description | Quantity | Newmar Part # |
SEAL FOAM SCRN DR | 1 ft. | 03650 |
FLAT RATE CODE:
22V 748
LABOR TIME:
.5 hr.
DEALER ACTION
Contact your Newmar Service Account Manager to obtain authorization and order part(s).
CUSTOMER ACTION
Contact the Newmar brand specialist immediately at 1-800-731-8300. An associate will assist you in making an appointment to have this repair completed.
IMPORTANT: Please read this bulletin in its entirety prior to beginning any diagnosis or repairs.
NOTICE: Any technical information published in this bulletin is intended for use only by a qualified, Newmar-authorized service technician. Newmar is not responsible for the misuse of this information.
Work Instructions for Bulletin 590 :: Brake Pedal/Dash Clearance Issue
- Measure and mark the dash cut, or print the attached template, and cut out the upper and lower template for a pattern to mark the dash cut.
- Using an air saw or a similar cutting device, cut slowly along the marks made in the previous step, making sure no wires are in the path of the blade. If you try to cut too fast, you may melt the plastic back together.
- After cutting, use 80 grit sandpaper to de-bur the cut plastic on the dash, and discard the plastic piece that was removed.
- Add a piece of foam tape to the back side of the dash in line with the brake pedal arm. This will eliminate dash rattling if the pedal arm is still close while driving with the pedal assembly fully extended.
Chronology :
Newmar Corporation is reporting this recall following the notification from a dealer on 9/12/22 that a driver delivering a unit noticed brake pedal catching the dash panel when it was extended towards him in the driver seat. This was causing the brakes to drag on the motorhome.
On 9/13/22 Newmar production tested the brake pedal by extending it out completely towards the driver and noticed the interference with the dash panel.
On 9/14/22 the Newmar Warranty Reduction team was notified of the problem to start working on a review of the issue and next steps to be taken.
On 9/20/22 and Engineering change order was written to trim the dash panel in the area of the brake pedal to give more clearance and removed the chance of any interference of the brake pedal with the dash panel. The was implemented immediately in production and all units still on Newmar property already through production also had the dash panel trimmed.
All of this information was presented to the Safety Committee on 10/5/2022 and at that time it was decided to file a recall for this issue.
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
NEWMAR | DUTCH STAR | 2023 |
9 Associated Documents
Recall Acknowledgement
RCAK-22V748-5794.pdf 645.745KB
Defect Notice 573 Report
RCLRPT-22V748-7676.PDF 213.969KB
Owner Notification Letter(Part 577)
RCONL-22V748-7230.pdf 204.106KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V748-6102.PDF 211.118KB
573 Report Cover Letter
RMISC-22V748-4368.pdf 176.198KB
573 Main Body Brake Pedal
RMISC-22V748-3084.pdf 197.887KB
Remedy Instructions and TSB
RCRIT-22V748-0626.pdf 1752.287KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V748-0596.PDF 211.219KB
Recall Quarterly Report #3, 2023-2
RCLQRT-22V748-8614.PDF 211.303KB
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=22V748&docType=RCL
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SEOCONTENT-START
NEWMAR CORPORATION NEWMARCORP.COM NEWMAR CORPORATION · 355 N DELAWARE ST · NAPPANEE, IN 46550-0030 (574) 773-7791 · FAX (574) 773-5153 · WWW.NEWMARCORP.COM Page 1 of 1 10/06/2022 VIA E-MAIL RECEIPT CONFIRMATION REQUESTED Mr. Greg Rea Associate Administrator for Enforcement NHTSA NEF-200, Room W45-306 1200 New Jersey Avenue, SE Washington, DC 20590 Re: Newmar Corporation Part 573 Defect and Noncompliance Information Report Mr. Rea: Following is a compulsory ‘defect and noncompliance information report’ pursuant to 49 U.S.C. Chapter 301 and 49 CFR Part 573.6. Newmar Corporation is reporting this recall campaign concerning possible interference with a fully extended brake pedal coming in contact with the dash panel causing unknown partial brake engagement. Newmar Corp. will assume responsibility for coordinating and executing this recall, in its entirety. If you need any additional information regarding this recall campaign, please feel free to contact me at (574) 773-7791, Ext. 3443. Sincerely, Rodney Newcomer Codes and Compliance Manager Newmar Corporation rnewcomer@newmarcorp.com
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NEWMAR CORPORATION NEWMARCORP.COM NEWMAR CORPORATION · 355 N DELAWARE ST · NAPPANEE, IN 46550-0030 (574) 773-7791 · FAX (574) 773-5153 · WWW.NEWMARCORP.COM Page 1 of 3 10/06/2022 Defect and Noncompliance Information Report Newmar Corporation was made aware of a potential equipment defect relating to motor vehicle safety that may exist in the vehicles listed below. Newmar Corporation is furnishing notification to the National Highway Traffic Safety Administration pursuant to 49 U.S.C. Chapter 301 and 49 CFR Part 573.6. Newmar Corporation’s campaign identification number will be assigned by NHTSA. Final Stage Vehicle Manufacturer Newmar Corporation 355 N Delaware St. Nappanee, IN 46550-0030 Inquiries should be directed to: Sherrena Beer Consumer Affairs Newmar Corporation 355 N. Delaware St. Nappanee, IN 46550-0030 Phone: (574) 773-7791 Fax: (574) 773-2007 Identification of Vehicles The vehicle models involved in this recall are: 2023 Dutch Star motorhomes. These vehicles were manufactured by Newmar Corporation between 1/20/2022 and 8/18/2022. Comprehensive Vehicle Population The total number of vehicles included in this campaign is 32. Effected Population Assessment 100% of the vehicles identified above may contain defective equipment. Page 2 of 3 Defect Description On certain Newmar Dutch Star class A motorhomes built on both Spartan and Freightliner chassis it was discovered that when the adjustable brake pedal is fully extended towards the driver the pedal may contact the dash panel causing it to have unknown partial brake engagement. If the brake is unknowingly engaged for a long period of time, it could cause brake overheating which could cause brake failure. The potential of brake overheating, and possible failure increase the risk for a crash. Manufacturer: Newmar Corporation 355 N. Delaware St. Nappanee, IN 46550 Ph. 574-773-7791 Principle Event Chronology Newmar Corporation is reporting this recall following the notification from a dealer on 9/12/22 that a driver delivering a unit noticed brake pedal catching the dash panel when it was extended towards him in the driver seat. This was causing the brakes to drag on the motorhome. On 9/13/22 Newmar production tested the brake pedal by extending it out completely towards the driver and noticed the interference with the dash panel. On 9/14/22 the Newmar Warranty Reduction team was notified of the problem to start working on a review of the issue and next steps to be taken. On 9/20/22 and Engineering change order was written to trim the dash panel in the area of the brake pedal to give more clearance and removed the chance of any interference of the brake pedal with the dash panel. The was implemented immediately in production and all units still on Newmar property already through production also had the dash panel trimmed. All of this information was presented to the Safety Committee on 10/5/2022 and at that time it was decided to file a recall for this issue. Newmar Corporation is not aware of any property damage, injury, or death, in vehicles manufactured by Newmar Corporation, attributed directly or indirectly to this defect. At the time of this letter Newmar Corporation has not received any warranty claims for this recall. Defect Remedy Program Newmar Corporation will be conducting this recall in its entirety. Units identified as having the brake pedal interference problem will have the dash panel trimmed to add more clearance at the brake pedal and dash panel. This will remove any chance of future brake pedal interference with the dash panel. All work will be at no cost to customer. Page 3 of 3 If the customer has had the repair performed before receiving this letter, they may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy. For additional information, contact Newmar Corporation at: Service Department Newmar Corporation 355 N Delaware St Nappanee, IN 46550-0030 Distributed Notices and Other Communications None This report prepared by: Rodney Newcomer Codes and Compliance Manager Newmar Corporation
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Newmar Corporation PO Box 30 Nappanee, IN 46550 RSB 590 NHTSA #22V 748 November 01, 2022 TC #2022-569 IMPORTANT: Please read this bulletin in its entirety prior to beginning any diagnosis or repairs. NOTICE: Any technical information published in this bulletin is intended for use only by a qualified, Newmar-authorized service technician. Newmar is not responsible for the misuse of this information. RECALL SERVICE BULLETIN AFFECTED MODELS 2023 :: Dutch Star DESCRIPTION The dash interferes with full extension of the brake pedal assembly. ISSUE Newmar Corporation has decided that a defect, which relates to motor vehicle safety, exists in specific motorhomes built on Freightliner and Spartan Chassis. On certain Newmar motorhomes, when the adjustable brake pedal is fully extended towards the driver, it may contact the dash panel. This can cause the brakes to partially be applied. Continuing to drive with the brakes partially applied may cause the brakes to overheat and cause a brake failure. UNITS AFFECTED Please refer to the attached population list for affected units and VINs. CORRECTIVE ACTION Follow the attached work instructions to trim the plastic dash panel. PARTS NEEDED Item Description Quantity Newmar Part # SEAL FOAM SCRN DR 1 ft. 03650 FLAT RATE CODE: 22V 748 LABOR TIME: .5 hr. DEALER ACTION Contact your Newmar Service Account Manager to obtain authorization and order part(s). CUSTOMER ACTION Contact the Newmar brand specialist immediately at 1-800-731-8300. An associate will assist you in making an appointment to have this repair completed. Work Instructions for Bulletin 590 :: Brake Pedal/Dash Clearance Issue 1. Measure and mark the dash cut, or print the attached template, and cut out the upper and lower template for a pattern to mark the dash cut. 2. Using an air saw or a similar cutting device, cut slowly along the marks made in the previous step, making sure no wires are in the path of the blade. If you try to cut too fast, you may melt the plastic back together. 3. After cutting, use 80 grit sandpaper to de-bur the cut plastic on the dash, and discard the plastic piece that was removed. 4. Add a piece of foam tape to the back side of the dash in line with the brake pedal arm. This will eliminate dash rattling if the pedal arm is still close while driving with the pedal assembly fully extended.
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NEWMAR CORPORATION . NEWMARCORP.COM NEWMAR CORPORATION · 355 N DELAWARE ST · NAPPANEE, IN 46550-0030 (800) 731-8300 · WWW.NEWMARCORP.COM P A Page 1 of 2 IMPORTANT SAFETY RECALL This notice applies to your vehicle VIN. #_______________________ Name Address City, State Zip code Date: 10/24/2022 Motor Vehicle Recall Notification – Recall Campaign No. 22V-748 Dear Valued Customer: This notice is being sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL Newmar Corporation has decided that a defect, which relates to motor vehicle safety exists on certain Newmar Motorhomes built on both Freightliner and Spartan chassis. When the adjustable brake pedal is fully extended towards the driver, it may contact the dash panel. This can cause the brakes to partially apply. If you continue to drive with the brakes partially applied, the brakes could overheat and cause a brake failure. These motorhomes require immediate service. Continued use poses a potential safety hazard. The Safety Risk Overheated brakes or a brake failure could increase the risk of a crash. WHAT WE WILL DO Newmar Corp. will provide owners of all affected motorhomes a remedy for the potential defect at no charge for parts or labor. The dash panel will be inspected and trimmed to eliminate the contact with the adjustable brake pedal when it is fully extended towards the driver. The total expected time for repair is .5 hrs. However, due to scheduling times the service provider may need the vehicle longer. WHAT YOU NEED TO DO As this defect does affect motor vehicle safety, it is recommended that you call Newmar service department immediately at 1-800-731-8300. An associate will assist you in making an appointment to have this repair completed. Federal regulations require that any vehicle lessor receiving this recall notification must forward a copy of this notice to the lessee within ten days. If you have had the repair performed before receiving this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy. For additional information, contact Newmar Corporation at: Service Department Newmar Corporation 355 N Delaware St Nappanee, IN 46550-0030 Newmar dealers are best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. HOWEVER, if you take your vehicle to your dealer on the scheduled date and this condition is not remedied on that date or within five days; please contact the Newmar Corporation Customer Service Department at 1-800-731-8300. You may also submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. NEWMAR CORPORATION · 355 N DELAWARE ST · NAPPANEE, IN 46550-0030 (574) 773-7791 · Fax (574)773-5153 · WWW.NEWMARCORP.COM P A Page 2 of 2 If you no longer own this vehicle, please furnish us the complete name, phone number, e-mail and physical address of the person or dealership you sold or traded your vehicle to. Thank you for your cooperation. Your safety and satisfaction with your Newmar product is important to us and we regret any inconvenience to you. Sincerely, Newmar Corporation
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-748 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Newmar Corporation Submission Date : OCT 07, 2022 NHTSA Recall No. : 22V-748 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Newmar Corporation Address : 355 North Delaware Street PO Box 30 Nappanee IN 46550 Company phone : 574-773-7791 Population : Number of potentially involved : 32 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2023-2023 Newmar Dutch Star Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : On certain Newmar Dutch Star class A motorhomes built on both Spartan and Freightliner chassis it was discovered that when the adjustable brake pedal is fully extended towards the driver the pedal may contact the dash panel causing it to have unknown partial brake engagement. If the brake is unknowingly engaged for a long period of time, it could cause brake overheating which could cause brake failure. The potential of brake overheating, and possible failure increase the risk for a crash. Dutch Star = 32 Production Dates : JAN 20, 2022 – AUG 18, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On certain Newmar Dutch Star class A motorhomes built on both Spartan and Freightliner chassis it was discovered that when the adjustable brake pedal is fully extended towards the driver the pedal may contact the dash panel causing it to have unknown partial brake engagement. If the brake is unknowingly engaged for a long period of time, it could cause brake overheating which could cause brake failure. The potential of brake overheating, and possible failure increase the risk for a crash. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : The potential of brake overheating, and possible failure increase the risk for a crash. Description of the Cause : On certain Newmar Dutch Star class A motorhomes built on both Spartan and Part 573 Safety Recall Report 22V-748 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Freightliner chassis it was discovered that when the adjustable brake pedal is fully extended towards the driver the pedal may contact the dash panel causing it to have unknown partial brake engagement. Identification of Any Warning that can Occur : Possible smell of hot brakes Involved Components : Component Name 1 : Dutch Star Dash Component Description : Dash Panel in front of driver seat Component Part Number : NR Supplier Identification : Component Manufacturer Name : Newmar Corp Address : 355 N. Delaware St PO Box 30 Nappanee Indiana 46550 Country : United States Chronology : Newmar Corporation is reporting this recall following the notification from a dealer on 9/12/22 that a driver delivering a unit noticed brake pedal catching the dash panel when it was extended towards him in the driver seat. This was causing the brakes to drag on the motorhome. On 9/13/22 Newmar production tested the brake pedal by extending it out completely towards the driver and noticed the interference with the dash panel. On 9/14/22 the Newmar Warranty Reduction team was notified of the problem to start working on a review of the issue and next steps to be taken. On 9/20/22 and Engineering change order was written to trim the dash panel in the area of the brake pedal to give more clearance and removed the chance of any interference of the brake pedal with the dash panel. The was implemented immediately in production and all units still on Newmar property already through production also had the dash panel trimmed. All of this information was presented to the Safety Committee on 10/5/2022 and at that time it was decided to file a recall for this issue. Part 573 Safety Recall Report 22V-748 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Newmar Corporation will be conducting this recall in its entirety. Units identified as having the brake pedal interference problem will have the dash panel trimmed to add more clearance at the brake pedal and dash panel. This will remove any chance of future brake pedal interference with the dash panel. All work will be at no cost to customer. How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Newmar will notify customers and dealers on or before 60 days from the date of this filing. Planned Dealer Notification Date : DEC 06, 2022 – DEC 06, 2022 Planned Owner Notification Date : DEC 06, 2022 – DEC 06, 2022 * NR – Not Reported
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