426-1615 Brake Wire Routed Incorrectly – 2023 Palomino Puma Pause Travel Trailers

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March 24, 2023 NHTSA CAMPAIGN NUMBER: 23V202000

Brake Wire Routed Incorrectly

A pinched brake wire may cause the brakes to fail, increasing the risk of a crash.

 

NHTSA Campaign Number: 23V202

Manufacturer Forest River, Inc.

Components EQUIPMENT, SERVICE BRAKES

Potential Number of Units Affected 19

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2023 Puma Pause travel trailers. The brake wire was routed incorrectly through the suspension, which may result in a pinched wire.

 

Remedy

Dealers will inspect the wire, and rewire or reroute as necessary, free of charge. Owner notification letters were mailed April 3, 2023. Owners may contact Forest River Customer Service at 1-574-327-2681. Forest River’s number for this recall is 426-1615.

 

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.

 


PUMA PAUSE TRAILER

BRAKE WIRING INSPECTION PROCEDURE

 

INTRODUCTION

The Puma Pause (20.2 & 20.3) Independent Suspension System has four (4) individual hubs/axles attached to four (4) independent swing-arms. The inspection interest can be found at the point where each electric brake wire exits from each swing-arm.

FLOORPLAN ITEM TO BE INSPECTED ITEM LOCATION NUMBER OF LOCATIONS
Puma Pause Trailer

20.2 & 20.3

Brake Wire Independent Suspension

Point of brake wire exit from each swing-arm

Per trailer – four (4)

 

Step 1

On each of the four (4) swing-arms, locate the exit point for the electric brake wire.

 

Once located, forward of the wire (butt) connectors, firmly grasp the wire with two or three fingers; push the wire in (toward the front of the trailer) and pull the wire back (toward the rear of the trailer) with enough force to determine whether or not the wire is able to freely move forward and rearward in the swing-arm. Note the while the length of movement may vary, the inspection interest is specific to free range of non-forced movement.

 

Step 2

IF free (non-forced) fore and aft (longitudinal) motion is present – no further action is required.

IF free (non-forced) fore and aft (longitudinal) motion is NOT present OR brake wire is severed/pulls out of swing-arm – Contact Forest River Puma Pause Customer Service.

 

Questions

MORryde Parts Department | 574-293-1581 or parts@morryde.com

Forest River Puma Pause | 574-825-7000 or ownerrelations@forestriverinc.com

 

At MORryde, we have a passion for solving problems. Whether we’re fabricating custom solutions, modifying a commercial chassis, or creating our innovative products, we answer to a wide range of markets and deliver on a variety of needs. At MORryde, it’s simply about doing MORE for our customers, and it doesn’t stop at the sale. We stand behind our products, believing in quality first, service always. No matter the issue, we’ll be the first to respond and the last to be satisfied. In short, we build better — together.

 

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PUMA PAUSE  TRAILER

I.S. BRAKE WIRE REPAIR INSTRUCTIONS

 

INTRODUCTION

The Puma Pause (20.2 & 20.3) Independent Suspension System has four (4) individual hubs/axles attached to four (4) independent swing-arms. The inspection interest can be found at the point where each electric brake wire exits from each swing-arm.

Kit Includes:

Item Qty Part
1 4 U-Bolts
2 8 Lock Nuts
3 1 3′ length Brake Wire
4 2 Gel Cap Wire Splice Connector
5 2 Heat Shrink Waterproof Butt Splice Connectors (yellow)

 

Tools Required:

 

INSTRUCTIONS

Step 1

Using the Garmin Tablet:

a. Select the suspension icon on the lower right corner of the tablet – highlighted blue in the picture.

b. Select the camping icon on the left side of the screen – highlighted orange in the picture.

c. Select the “KNEEL” option to lower the trailer.

 

Step 2

Ensure that the wheels on the non-affected side of the trailer have been chocked.

 

Step 3

Ensure that the wheels on the non-affected side of the trailer have been chocked.

 

Step 4

On the affected side of the trailer, lift the frame slightly then support with a jack stand.

 

Step 5

Use a floor jack to support the swing-arm of the affected axle.

 

Step 6

With the affected wheel off the ground, spin the tire, then engage the brake to determine whether or not the brake is functioning properly.

 

Step 7

Remove both forward and rear wheel from the affected side.

 

Step 8

If in Step 6 the brake IS functioning properly, DO NOT cut/ sever the brake wire yet. If the brake IS NOT functioning properly, cut/sever (at the butt connector) the affected brake wire.

 

Step 9

Remove affected axle from the swing-arm by removing 8 lock nuts and 4 U-Bolts that secure the axle.

If the brake IS functioning properly, lift the axle and inspect the wire. If there is no damage to the wire, proceed to Step 16 for reassembly. If the brake is NOT functioning properly, or upon inspection it is determined that the wire is damaged in any

 

If in Step 6 the brake IS functioning properly, DO NOT cut/ sever the brake wire yet. If the brake IS NOT functioning properly, cut/sever (at the butt connector) the affected brake wire.

 

way, cut/sever (at the butt connector) the affected brake wire and proceed to Step 10.

Step 10

Locate and remove access cover located near the front of the swing-arm on the road-side of the coach.

 

Step 11

Pull/free excess brake wire free of spray foam from the belly pan.

 

Step 12

Pull affected brake wire through/out of it’s entrance point located at the front of the swing-arm.

 

Step 13

If you are replacing the wire on the curb-side of the trailer, you will need to use the damaged wire to pull the new wire through the crossmember to the wire access on the road-side of the coach. Then you can feed the wire through the grommet and the swing-arm. It is easier to feed the wire through the grommet with the grommet loose from the swing-arm, then once the wire is all the way through the swing-arm, use a screwdriver to insert the grommet into the hole in the swing-arm.

 

Step 14

Cut/sever affected brake wire at the gel cap connection and splice in new/replacement wire with the gel cap connectors supplied in the kit.

 

Step 15

Replace access cover.

 

Step 16

Prior to re-seating axle, ensure that the brake wire rests against the swing-arm tube wall out of the way/free of the axle locator.

 

Step 17

Ensuring that the replacement brake wire is free of the axle locator, position the axle back into the swing-arm – ensuring that the locator is appropriately seated on/ around the locator bolt.

 

Step 18

Using four (4) U-Bolts and eight (8) Lock Nuts provided in the kit, secure the axle to the swing-arm and torque lock nuts to 80ft lbs, consistent with the diagram provided at the end of this instruction.

NOTE: As U-Bolts are being tightened, ensure that the brake wire remains clear of the axle locator/seat.

Ensure that the new brake wire has free fore-aft movement in the swing-arm.

 

Step 20

Using the supplied butt connectors, splice connect the brake wires to the hub – once crimped, apply heat to the connectors to activate the heat-shrink.

 

Step 21

Reattach the wheels on affected side and tighten (not torque) the lug nuts.

 

Step 22

Remove jacks/support from each swing-arm.

 

Step 23

Remove jack/support from frame, then torque lug nuts to 100ft lbs, consistent with the diagram provided below at the end of this instruction.

 

Step 24

Restore power to suspension system by reinserting fuse.

 

Step 25

Test brakes.

 

A 6 Lug Nut Torque pattern

 

At MORryde, we have a passion for solving problems. Whether we’re fabricating custom solutions, modifying a commercial chassis, or creating our innovative products, we answer to a wide range of markets and deliver on a variety of needs. At MORryde, it’s simply about doing MORE for our customers, and it doesn’t stop at the sale. We stand behind our products, believing in quality first, service always. No matter the issue, we’ll be the first to respond and the last to be satisfied. In short, we build better — together.

 

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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 2023 Pause 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 brake wire was routed by the component supplier through a pinch-point in the suspension.

 

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

If the brake wire becomes pinched in the suspension, it may damage or break the brake wire. The trailer brakes will not activate which may lead to property damage, crash, injury and/or death.

 

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. However, 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. An inspection will be performed to determine if the wire is affected by the pinch point. If the wire is affected by the pinch point, the rewiring and rerouting procedure supplied by MORryde will be performed. 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 2.0 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:

Pause
Forest River, Inc.
Attn: WARRANTY MANAGER
520 Gerber Street
Ligonier, IN 46767

 


Chronology :

On March 22, 2023, Forest Rivers Office of Corporate Compliance (“OCC”) was notified by the plant of one consumer complaint regarding the brake wire routed through a pinch point in the suspension. Upon review with the plant it was determined that all vehicles since inception of these models could be affected.

On March 24, 2023, Forest Rivers Corporate Recall Committee voted to recall.

On April 4, 2023, Pause Manufacturing plants’ manager contacted OCC stating that the Puma name is incorrectly stated. The vehicle is a Forest River Inc. Pause travel trailer. Amending to remove the “Puma” from the 573 report.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
PALOMINO PUMA PAUSE 2023

 


11 Associated Documents

Defect Notice 573 Report

RCLRPT-23V202-7130.PDF 214.637KB

 


Remedy Instructions and TSB

RCRIT-23V202-6540.pdf 10985.006KB

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Remedy Instructions and TSB

RCRIT-23V202-3424.pdf 5355.789KB

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Recall Acknowledgement

RCAK-23V202-7409.pdf 645.81KB

 


Recall 573 Report – 4/3/2023

RCLRPT-23V202-2802.PDF 214.779KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-23V202-4588.pdf 172.324KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V202-2365.pdf 210.295KB

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Recall Quarterly Report #1, 2023-2

RCLQRT-23V202-8492.PDF 211.121KB

 


Recall Quarterly Report #2, 2023-3

RCLQRT-23V202-2738.PDF 211.36KB

 


Recall Quarterly Report #3, 2023-4

RCLQRT-23V202-0393.PDF 211.444KB

 


Recall Quarterly Report #4, 2024-1

RCLQRT-23V202-8251.PDF 211.548KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V202&docType=RCL

 


 

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