110-1561 Cross-Member May Not Retain Holding Tanks – 2020-2021 Coachmen Shasta Phoenix, Coachmen Brookstone, & 2019-2022 Coachmen Chaparral, & Chaparral Lite Fifth Wheels

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October 31, 2022 NHTSA CAMPAIGN NUMBER: 22V813000

Cross-Member May Not Retain Holding Tanks

A tank that becomes dislodged during transit increases the risk of a crash.

 

NHTSA Campaign Number: 22V813

Manufacturer Forest River, Inc.

Components EQUIPMENT, STRUCTURE

Potential Number of Units Affected 2,018

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2020-2021 Coachmen Shasta Phoenix, Coachmen Brookstone, and 2019-2022 Coachmen Chaparral, and Chaparral Lite fifth wheels. The floating cross-member may not be installed correctly and fail to retain the holding tanks, causing the holding tanks to become dislodged.

 

Remedy

Dealers will inspect and relocate the cross-member as necessary, free of charge. Owner notification letters were mailed November 29, 2022. Owners may contact Forest River customer service at 1-574-825-7101. Forest River’s number for this recall is 110-1561.

 

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 2020-2021 Shasta Phoenix, Coachmen Brookstone, 2019-2022 Coachmen Chaparral and Chaparral Lite Fifth Wheel 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?

On certain vehicle’s, the floating cross-member may not fully engage and support the holding tank(s)

 

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

A tank dislodged while under towing conditions 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. Forest River will provide all parts and labor free of charge to Consumers and Dealers. An authorized Forest River Dealer or Service Center will need to inspect the tanks for the proper location of the existing floating cross-member that supports tank(s). If the cross-member is not adequately supporting the tank(s), it will be relocated to support the tank(s).

 

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 1.50 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:

Coachmen Fifth Wheels
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury, IN 46540

 


RECALL 22V813 / 2022-622 REMEDY INSTRUCTIONS

Make(s): MANY, SEE BELOW
Model(s): MANY, SEE BELOW
Model Year(s): 2019 – 2022
Repair Code: RC-672-13-00-004267
Allotted Time: 1.50 HRS.
Inspection Code: RC-672-05-00-004266
Allotted Time: .1.0 HRS
Concern:
On certain vehicles, the floating crossmember may have been installed whereas it may not fully engage and support the holding tank.
Photo(s) Required YES, PRE & POST
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.

 

CERTAIN: 2019 – 2020 – CHAPARRAL LITE – CLF30BHS

CERTAIN: 2020 – 2021 – CHAPARRAL LITE, CHAPARRAL, SHASTA PHOENIX & BROOKSTONE – CLF284RL, CHF367BH, SPF367BH & BKF398MBL

CERTAIN: 2020 – 2022 – CHAPARRAL – CHF373MBRB

CERTAIN: 2020 – SHASTA PHOENIX – SPF25MK, SPF381RE & SPF392BL

CERTAIN: 2021 – CHAPARRAL LITE, CHAPARRAL, SHASTA PHOENIX & BROOKSTONE – CLF30RLS, CHF360IBL, SPF274BH & BKF290RL

 

INSPECTION:

STEP 1: LOCATE AND REMOVE THE WASTE WATER (GREY AND BLACK WATER TANKS) UNDERBELLY PANEL(S);

 

STEP 2: INSPECT ALL WASTE WATER (GREY AND BLACK WATER TANKS) STEEL CROSS MEMBERS THAT HOLD THE TANK INTO THE UNDERBELLY;

  • EXCESSIVE GAP: A GAP IN WHICH THE WASTE TANK(S) MAY DISLODGE FROM THE FLOATING CROSS MEMBER AND FALL;
  • INSPECT THE FLOATING CROSS-MEMBER(S) FOR A MINIMUM OF TWO SELF-TAPPING FASTENERS IN EACH END;
  • INSPECT THE FLOATING CROSS-MEMBER(S) FOR EXCESSIVE GAP BETWEEN THE WASTE TANK AND THE STEEL CROSS MEMBER(S);
  • IF THE WASTE WATER TANK(S) HAVE EXCESSIVE GAP
    • TAKE PHOTO’S OF EXCESSIVE GAP
    • INDICATE MEASUREMENT BETWEEN HOLDING TANK(S) AND FLOATING CROSS MEMBER(S)
    • SUBMIT FOR REMEDY PRIOR AUTHORIZATION REVIEW;
  • IF THERE ARE NOT AT LEAST TWO (2) FASTENERS IN EACH END OF THE FLOATING CROSS MEMBER(S), MOVE ON TO REMEDY;
    • TAKE PHOTO’S OF MISSING FASTENER(S)
    • SUBMIT FOR REMEDY PRIOR AUTHORIZATION REVIEW;
  • IF THERE IS NOT EXCESSIVE GAP BETWEEN THE FLOATING CROSS MEMBER(S) AND THE WASTE WATER TANK(S) AND IF THERE ARE TWO (2) FASTENER(S) IN EACH END OF THE FLOATING CROSS MEMBER(S) THEN REPLACE UNDERBELLY PANELS;
  • CLAIM INSPECTION CODE ONLY.

 

REMEDY:

THE UNDERBELLY PANEL SHOULD ALREADY BE OUT OF THE WAY SINCE YOU HAVE INSPECTED AND ARE NOW INTO REMEDY.

ADDITIONALLY, ENSURE THE WASTE WATER HOLDING TANK(S) ARE PROPERLY EMPTIED.

 

STEP 1: WASTE WATER TANK(S) THAT HAVE EXCESSIVE GAP;

  • REMOVE AND SET ASIDE THE SELF-TAPPING FASTENER(S) FROM THE FLOATING CROSS MEMBERS EACH END;
    • THERE SHOULD BE A TOTAL OF FOUR (4) SELF-TAPPING FASTENER(S) TO REMOVE;
    • IF LESS THAN FOUR (4), RETRIEVE ADDITIONAL SELF-TAPPING FASTENER(S) THE SAME SIZE AS WHAT WAS REMOVED AND SET ASIDE FOR REINSTALLATION THE CORRECT AMOUNT OF FASTENERS;

 

STEP 2: REINSTALL THE FLOATING CROSS MEMBER;

  • PUSH THE FLOATING CROSS MEMBER TIGHTLY AGAINST THE HOLDING TANK(S) YOU ARE WORKING WITH;
  • REINSTALL THE FOUR (4) SELF-TAPPING FASTENER(S) THROUGH THE FLOATING CROSS MEMBER AND INTO THE CHASSIS;

 

STEP 3: REINSTALL THE UNDERBELLY PANELING;

 

STEP 4: CLAIM REPAIR CODE FOR REMEDY.

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Chronology :

Forest River’s Office of Corporate Compliance (“OCC) began reviewing warranty data on September 27, 2022 for the manufacturing plant as part of VOQ’s received.

On October 3, 2022, OCC met with plant leadership to discuss the warranty data and have the plant begin dissecting the data.

On October 7, 2022, OCC met with plant Leadership to discuss the warranty data and any new potential trends identified. It was agreed to by OCC and Plant Leadership that further dissection of the data was required by plant leadership.

On October 24, 2022, the warranty data review was completed. The data demonstrated a trend by certain vehicles upwards beginning in Quarter 1 of 2019, therefore Forest River decided to begin the scope date at January 1, 2019. Forest River decided to end the scope on August 31, 2021, in which OCC discovered that manufacturing began installing secondary straps to the water tanks.

Forest Rivers Corporate Recall Committee voted to recall on October 28, 2022.

A-1 On March 27, 2023, OCC filed and amendment to include warranty claims that were received as per NHTSA’s request on the acknowledgment letter. 59 warranty claims received between 11/8/2019 – 8/19/2022.

 


12 Affected Products

Vehicles

MAKE MODEL YEAR
COACHMEN BROOKSTONE 2020-2021
COACHMEN CHAPARRAL 2019-2022
COACHMEN CHAPARRAL LITE 2019-2022
SHASTA PHOENIX 2020-2021

 


10 Associated Documents

Recall Acknowledgement

RCAK-22V813-8306.pdf 646.281KB

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Defect Notice 573 Report

RCLRPT-22V813-7956.PDF 217.825KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V813-1826.pdf 172.067KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V813-2377.pdf 204.334KB

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Remedy Instructions and TSB

RCRIT-22V813-7241.pdf 153.233KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V813-5431.PDF 211.138KB

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Recall 573 Report – 3/27/2023

RCLRPT-22V813-2773.PDF 217.937KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V813-0912.PDF 211.235KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V813-2895.PDF 211.324KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V813-4667.PDF 211.322KB

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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=22V813&docType=RCL

 


 

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