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January 25, 2024 NHTSA CAMPAIGN NUMBER: 24V040000
Awning May Extend Unintentionally
An awning extending unintentionally during transit may become a distraction or road hazard, increasing the risk of a crash.
NHTSA Campaign Number: 24V040000
Manufacturer Forest River, Inc.
Components STRUCTURE, EQUIPMENT
Potential Number of Units Affected 2,519
Summary
Forest River, Inc. (Forest River) is recalling certain 2020-2023 Coachmen Galleria, 2021-2023 Forest River Beyond, and 2021-2023 Coachmen Nova Class B motorhomes. The retractable awning may extend unintentionally during transit.
Remedy
Dealers will install a wedge to support the internal components in the gearbox and replace the motor as necessary, free of charge. Owner notification letters were mailed February 9, 2024. Owners may contact Forest River Customer Service at 1-574-825-6319. Forest River’s number for this recall is 225-1723.
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.
RECALL 24V040 / 2024-035 REMEDY INSTRUCTIONS
Make(s): NOVA, BEYOND & GALLERIA
Model(s): MANY, SEE BELOW
Model Year(s): 2020 – 2023
Concern:
A gearbox housing has been observed to show a crack that may develop into a fracture. As a result of such fracture is a potential for release of the awning brake under certain in-use conditions.
Turn off LP Gas at LPG Tank(s). 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 – 2021 – 2023 NOVA: NAB20C, NAB20D & NAB20RB
CERTAIN – 2021 – 2023 BEYOND: BYB22CAWD, BYB22CFCD, BYB22CFEB, BYB22CRWD, BYB22DAWD, BYB22DFEB, BYB22DRWD,
BYB22RBAWD, BYB22RBEB & BYB22RBRWD
CERTAIN – 2020 – 2023 GALLERIA: GAB24AM, GAB24AM4X4, GAB24FLM, GAB24FLM4X4, GAB24QM, GAB24QM4X4, GAB24TM& GAB24TM4X4
PARTS TO ORDER:
1 – F100514931
REQUIREMENTS:
PHOTO(S) ARE REQUIRED OF ANY DAMAGED PARTS.
PHOTO OF THE AWNING SERIAL NUMBER.
REMEDY:
REVIEW THE DOCUMENTS ATTACHED TO THIS LETTER.
February 2024
This Notice applies to your vehicle VIN listed above.
Dear Forest River Customer:
This notice is sent to you 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 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome recreational vehicles.
WHAT IS THE DEFECT?
Cracks may develop in the gearbox housing, causing a fracture. As a result of such fracture the awning may unintentionally extend.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
An awning that extends unintentionally while the motor home is in motion could be a distraction and/or present a road hazard to the vehicle driver or oncoming traffic, which can 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. 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. The remedy will include installation of additional material (which the Company refers to as a “wedge”) intended to support the internal components inside certain Freestyle left-handed gearbox motor housing assemblies. If the motor needs replaced, the newly designed motor with the wedge will be installed. 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 1.0 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:
CRV Class B
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury IN, 46540
Chronology :
On January 12, 2024, Forest Rivers Office of Corporate Compliance (“OCC”) received a equipment recall 23E096 that was provided to the manufacturing division on January 11, 2024. The same day, OCC asked Carefree of Colorado to provide sales information, in an effort to identify if the awnings had been used in manufacturing.
On January 16, 2024, OCC inquired again with Carefree of Colorado concerning the sales information.
On January 18, 2024, OCC received remedy instructions and was told that Carefree of Colorado was evaluating the data requested by OCC.
On January 22, 2024, OCC inquired again with Carefree of Colorado concerning the sales information.
On January 23, 2024, OCC received information from Carefree and followed up with Carefree of Colorado on January 24, 2023, in regard to questions of the dates.
On January 25, 2024, OCC determined that the subject awnings were in use in Model Year 2021 – 2023.
On January 25, 2024, Forest River filed a recall in reference to Equipment recall 23E096.
23E096 – Awning May Extend Unintentionally – Carefree Freestyle Gearbox Housing
23E096 – Awning May Extend Unintentionally – Carefree Freestyle Gearbox Housing
10 Affected Products
Vehicles
MAKE | MODEL | YEAR |
COACHMEN | BEYOND | 2021-2023 |
COACHMEN | GALLERIA | 2020-2023 |
COACHMEN | NOVA | 2021-2023 |
6 Associated Documents
Recall Acknowledgement
RCAK-24V040-2823.pdf 646.084KB
Defect Notice 573 Report
RCLRPT-24V040-1645.PDF 216.039KB
Miscellaneous Document – RCMN-23E096-1303
RMISC-24V040-6683.pdf 166.256KB
Manufacturer Notices(to Dealers,etc)
RCMN-24V040-7735.pdf 203.645KB
Remedy Instructions and TSB
RCRIT-24V040-9518.pdf 1540.133KB
ISSUED Owner Notification Letter(Part 577)
RCONL-24V040-1133.pdf 241.973KB
Latest Recalls Documents
For the Latest and Most recent Recall Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V040&docType=RCL
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SEOCONTENT-START
Attorney-Client Privilege
Attorney Work Product
DRAFT
2145 W. 6th Avenue Broomfield, CO 80020 Phone: 303.469.3324 Fax: 303.469.4742 www.carefreeofcolorado.com
SAFETY RECALL NOTICE December __, 2023 RE: NHTSA Campaign Number _______
Carefree of Colorado Freestyle Awning Part No. 015933-001
Dear Industry Partner:
As a follow up to our prior communications, this notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Carefree of Colorado (“Carefree”) is requesting your assistance in the above-referenced NHTSA campaign. Carefree has decided that a defect which relates to motor vehicle safety may exist in certain Freestyle left-hand gearbox motor housing assemblies (the “Gearbox Housings”) in production from February 27, 2020 to November 1, 2022.
Carefree is notifying the owners of the affected Gearbox Housings in order to correct the problem. They will be directed to the appropriate RV dealership for inspection/repair. A copy of this owner notification letter is attached for your information and in the event you wish to send it to your customers directly.
Carefree’s primary concern is the safety of our customers. We thank you in advance for your cooperation and understanding in this matter.
What is the problem?
There is a potential for cracks to develop in the Gearbox Housing. In a fraction of a percent of units, a Gearbox Housing has been observed with a crack that may develop into a fracture. In the event of a fracture, there is appears to be a potential for release of the awning brake under certain in-use conditions. An awning that extends unintentionally while a motor home is in motion could be a distraction and/or present a road hazard to the vehicle driver or surrounding traffic, which can increase the risk of a crash without prior warning. As a precaution, owners have been advised that they should manually secure the awnings to reduce the potential for unintentional awning extension until they are able to bring their vehicle in to a dealership for inspection.
What will Carefree do?
Carefree will provide a field modification instruction and additional support for the internal components of the Gearbox Housing, which will alleviate the risk outlined in this notice. The remedy outlined in this notice will be provided at no cost to the owner.
Attorney-Client Privilege
Attorney Work Product
DRAFT
2145 W. 6th Avenue Broomfield, CO 80020 Phone: 303.469.3324 Fax: 303.469.4742 www.carefreeofcolorado.com
What should you do?
According to our records, the affected Gearbox Housings were purchased by your company. Beginning February ____, 2024, owners have been asked to bring their motor homes to their RV dealerships so the awning and Gearbox Housing can be inspected. This inspection should be scheduled at your mutual convenience.
If, during the inspection, no crack is observed in the Gearbox Housing, an additional support wedge will be installed. If, however, a crack in the Gearbox Housing is observed, a new Motor and additional support wedge will be installed. Please itemize the above-referenced NHTSA campaign number—XXXXXX—as completed work on your invoice (separate from any other charges) and include the owner’s name, address, and phone number, as well as the VIN, as a part of this repair when submitting your invoice to Carefree.
How do you obtain components and labor approval?
Dealer Labor Allowance(s):
•
Inspection and additional support installation: 0.50 Hours
•
Replace Cracked Gearbox Housing (if required): 0.75 Hours
To obtain the no-charge, additional support components or in the case of a crack, a new Gearbox Housing as well as pre-authorization to perform the repairs, please submit your request to warranty@carefreeofcolorado.com. Include the Carefree awning serial number (located on the inside of the lead rail) and the vehicle VIN (on the OEM Federal Placard located on the driver’s side door jamb) with your submission. This information will provide a record of the awning repair.
If you have any questions your Carefree contacts for this recall are:
•
Regina Whitehorse, rwhitehorse@carefreeofcolorado.com Phone: 303-410-6328
•
Peggy Dunbar, pdunbar@carefreeofcolorado.com Phone: 303-410-6214
•
Nancy Vickery, Nvickery@carefreeofcolorado.com Phone: 303-410-6319
What if the owner already paid for the repair?
In the event you are contacted by an owner who previously paid for a repair addressing the issue described in this notice, the owner has been advised to have their vehicle inspected by an authorized dealer to ensure that the correct replacement parts were used.
Attorney-Client Privilege
Attorney Work Product
DRAFT
2145 W. 6th Avenue Broomfield, CO 80020 Phone: 303.469.3324 Fax: 303.469.4742 www.carefreeofcolorado.com
The owner also may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall.
If an owner contacts you regarding a pre-notification remedy of the problem associated with this recall, please advise the owner to submit a refund request directly to Carefree of Colorado, 2145 W. 6th Avenue, Broomfield, CO 80020. When mailing the refund request, the owner should include a copy of their original repair receipt and any other supporting documents evidencing that a repair was made.
IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by the notification under a sale or lease until the defect or noncompliance is remedied.
If you have questions or require additional assistance, please contact Carefree. Carefree thanks again you for your cooperation and understanding.
Carefree of Colorado
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-040
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River, Inc. JAN 25, 2024 NHTSA Recall No. : 24V-040 Manufacturer Recall No. : 225-1723
Manufacturer Information :
Manufacturer Name : Forest River, Inc.
Address : 55470 CR 1
P.O. Box 3030 Elkhart IN 46515-3030 Company phone : 1-800-348-7440
Population :
Number of potentially involved : 2,519 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2020-2023 Forest River Inc. Coachmen Galleria Class B Motorhomes Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by sales records from Carefree provided to OCC. See Attached Spreadsheet for Model and Quantity
Production Dates : MAR 02, 2020 – MAR 09, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2021-2023 Forest River Inc. Beyond Class B Motorhomes Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by sales records from Carefree provided to OCC. See attaches spreadsheet for model and quantities. Production Dates : MAR 02, 2020 – MAR 09, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2023 Forest River Inc. Coachmen Nova Class B Motorhomes Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by sales records from Carefree provided to OCC. See attaches spreadsheet for model and quantities. Production Dates : MAR 02, 2020 – MAR 09, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-040 Page 2 Description of Defect :
Description of the Defect : According to Carefree of Colorado Recall 23E096: “There is a potential for cracks to develop in the gearbox housing. In a fraction of a percent of units, a gearbox housing has been observed to show a crack that may develop into a fracture. As a result of such fracture is a potential for release of the awning brake under certain in-use conditions.”
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : According to Carefree of Colorado Recall 23E096: “An awning that extends
unintentionally while the motor home is in motion could be a distraction and/or present a road hazard to the vehicle driver or oncoming traffic, which can increase the risk of a crash.
Description of the Cause : Unknown Identification of Any Warning
that can Occur : Unknown Involved Components : Component Name 1 : Motor Assembly, Small Box, 12V DC, Left Hand Component Description : Motor Assembly, Small Box, 12V DC, Left Hand Component Part Number : 015933-001 Supplier Identification : Component Manufacturer
Name : Carefree Of Colorado Address : 2145 W 6th Avenue
Broomfield Colorado 80020
Country : United States Chronology :
On January 12, 2024, Forest Rivers Office of Corporate Compliance (“OCC”) received a equipment recall 23E096 that was provided to the manufacturing division on January 11, 2024. The same day, OCC asked Carefree of Colorado to provide sales information, in an effort to identify if the awnings had been used in manufacturing. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-040 Page 3 On January 16, 2024, OCC inquired again with Carefree of Colorado concerning the sales information. On January 18, 2024, OCC received remedy instructions and was told that Carefree of Colorado was evaluating the data requested by OCC. On January 22, 2024, OCC inquired again with Carefree of Colorado concerning the sales information. On January 23, 2024, OCC received information from Carefree and followed up with Carefree of Colorado on January 24, 2023, in regard to questions of the dates. On January 25, 2024, OCC determined that the subject awnings were in use in Model Year 2021 – 2023. On January 25, 2024, Forest River filed a recall in reference to Equipment recall 23E096. Description of Remedy :
Description of Remedy Program : Forest River will provide all parts and labor free of charge to Consumers
and Dealers. An authorized Forest River dealer will need to perform the remedy. The remedy will include installation of additional material (which the Company refers to as a “wedge”) intended to support the internal components inside certain Freestyle left-handed gearbox motor housing assemblies. If the motor needs replaced, the newly designed motor with the wedge will be installed. What is the Forest River Customer Service Phone Number? (574) 825-6319 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: CRV Class B Forest River, Inc.
Attn: WARRANTY MANAGER PO Box 30
Middlebury IN, 46540 How Remedy Component Differs from Recalled Component : Carefree Of Colorado – (800) 621-2617 2145 W 6th Avenue
Broomfield, CO 80020 The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-040
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Affected Component – According to Carefree of Colorado Recall 23E096: “Motor Assembly, Small Box, 12V DC, Left Hand”
P/N – 015933-001
Replacement Components:
R002066-001 – Screws and Wedge
R002066-002 – Screws, Wedges, & Replacement Motor
The Company will apply the remedy from NHTSA Campaign Number
22E-094, by coordinating the installation of additional material (which the Company refers to as a “wedge”) intended to support the internal components inside certain Freestyle left-handed gearbox motor housing assemblies.
Identify How/When Recall Condition was Corrected in Production :
According to Carefree of Colorado Recall 23E096: “On November 1, 2022. the Company issued a stop shipment and stop production order that applied to right-hand gearbox motor housing assemblies at issue in NHTSA Campaign Number 22E-094. The Company has since added the wedge as part of all right-hand and left-hand gearbox motor housing assemblies in initial production. Recall Schedule :
Description of Recall Schedule : Forest River has the utmost urgency in our recalls. Forest River will send
suspected VIN numbers to our third party vendor that is licensed to pull data on the current owner of the vehicles (as needed) once a formal NHTSA I.D. is provided. Forest River intends on pushing the mailing out as soon as NHTSA provides any correction(s) and an Acknowledgement Letter.
Planned Dealer Notification Date : MAR 05, 2024 – MAR 05, 2024
Planned Owner Notification Date : MAR 05, 2024 – MAR 05, 2024
* NR – Not Reported
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RECALL 24V040 / 2024-035 REMEDY INSTRUCTIONS
Make(s): NOVA, BEYOND & GALLERIA
Model(s): MANY, SEE BELOW
Model Year(s): 2020 – 2023
Concern:
A gearbox housing has been observed to show a
crack that may develop into a fracture. As a
result of such fracture is a potential for release of
the awning brake under certain in-use conditions.
Repair Code: RC-042-01-00-004484
Allotted Time: .50 HRS.
Inspection Code: N/A
Allotted Time: N/A
Photo(s) Required: YES, SEE BELOW
Prior Authorization Required: YES
Part(s) Kit Number: F100514931
Part(s) Return: NO – DESTROY IN FIELD
Turn off LP Gas at LPG Tank(s). 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 – 2021 – 2023 NOVA: NAB20C, NAB20D & NAB20RB
CERTAIN – 2021 – 2023 BEYOND: BYB22CAWD, BYB22CFCD, BYB22CFEB, BYB22CRWD, BYB22DAWD, BYB22DFEB, BYB22DRWD,
BYB22RBAWD, BYB22RBEB & BYB22RBRWD
CERTAIN – 2020 – 2023 GALLERIA: GAB24AM, GAB24AM4X4, GAB24FLM, GAB24FLM4X4, GAB24QM, GAB24QM4X4, GAB24TM&
GAB24TM4X4
PARTS TO ORDER:
1 – F100514931
REQUIREMENTS:
PHOTO(S) ARE REQUIRED OF ANY DAMAGED PARTS.
PHOTO OF THE AWNING SERIAL NUMBER.
REMEDY:
REVIEW THE DOCUMENTS ATTACHED TO THIS LETTER.
Carefree of Colorado Left Hand Motor Wedge Installation Instruction FREESTYLE EVOLUTION
056513-002r1 1
SERVICE MANUAL
LEFT HAND MOTOR WEDGE
INSTALLATION
12V MOTORIZED RV ROOF MOUNTED BOX AWNING
Read this manual before installing or using this product. Failure to follow the
instructions and safety precautions in this manual can result in personal injury and/or
cause the product to not operate properly.
These instructions apply to all models listed. Details and procedures unique to a specific
model are labeled appropriately.
FREESTYLE EVOLUTION Left Hand Motor Wedge Installation Instruction Carefree of Colorado
2 056513-002r1
NOTICES AND DISCLAIMERS
SUPPLEMENTAL INSTRUCTIONS
These instructions are intended to be supplemental to the existing Freestyle Evolution service manual. If
there are additional questions on service, please refer to service manual (PN 070036-301).
SAFETY INFORMATION
This is the safety alert symbol. It is used to alert individuals to potential
personal injury hazards. Obey all safety messages that follow this symbol
to avoid possible personal injury or death.
WARNING Indicates a hazardous situation, which if not avoided, could result in death
or serious bodily injury.
CAUTION Indicates a hazardous situation, which if not avoided, may result in minor
or moderate bodily injury.
NOTICE Indicates a situation that may result in equipment-related damage.
General Safety:
WARNING This product can expose you to chemicals including Di-isodecyl phthalate
(DIDP), Vinyl Chloride and Formaldehyde, which are known to the state of California to cause
cancer or birth defects or other reproductive harm. For more information visit
www.P65warnings.ca.gov
WARNING Shock Hazard. Always disconnect battery or power source before
working on or around the electrical system.
WARNING Always wear appropriate safety equipment (i.e. goggles).
CAUTION Always use appropriate lifting devices and/or helpers when lifting or
holding heavy objects.
NOTICE When using fasteners, do not over tighten. Soft materials such as fiberglass and
aluminum can be “stripped out” and lose the ability to grip and hold.
Carefree of Colorado www.carefreeofcolorado.com a Scott Fetzer company
Carefree of Colorado Left Hand Motor Wedge Installation Instruction FREESTYLE EVOLUTION
056513-002r1 3
PRODUCT OVERVIEW
This manual covers the installation of a motor wedge into the existing Carefree Freestyle Evolution awning. The motor wedge is used to provide additional support to the motor in normal operations. Below is a schematic showing the motor wedge, a Left Hand motor is shown.
INSTALLING THE MOTOR WEDGE
WARNING If the awning is closed when the motor and end cap screws are removed, the spring arms will extend the awning quickly, possibly causing personal injury and damage to the awning.
1. Disconnect power to the awning.
2. If the awning is extended: Carefully push the lead rail toward the case so that the arms collapse. While holding the lead rail in this position, firmly tie the elbows of the spring arms together. Use a minimum 1/2″ rope – do not use bungee cords. When tying the rope, use a non-slip knot such as a square knot or equivalent.
3. If the awning is closed: Secure the lead rail in the closed position with at least 3 zip ties (tensile strength of 40lb or above) spaced equally along the awning.
CAUTION Failure to secure the lead rail as described will allow the spring arms to unexpectedly extend out possibly causing personal injury and damage to the awning.
FREESTYLE EVOLUTION Left Hand Motor Wedge Installation Instruction Carefree of Colorado
4 056513-002r1
4. Remove the motor end cap screw and remove the Endcap and set aside. For installed awnings, you may need to loosen the bracket bolts to gain access to the motor Endcap, depending on motorcoach model. Please reference service manual 070036-301 for additional information if you need to partially remove your awning to perform the motor wedge installation procedure.
5. Remove the motor screws (x2) and the endplate screws (x4) using either a T20 Torx head bit and the longer rail screw (x1) using a #2 Phillips head bit. Some awnings were installed with all 5 screws being the Phillips head screw.
6. Pull the endplate away from the case. Take care to not lose the small Endplate Spacer. The Motor Spacer should stay wedged inside the Endplate.
7. With a flashlight, inspect the motor housing. Do not remove the motor from the roller tube. Pay particular attention to this highlighted zone. Inspect for any cracks anywhere on the motor housing. If there are no cracks visible, then the motor can continue to be used.
8. If there are cracks, please follow the instructions detailed in the section REPLACING THE MOTOR in service manual 070036-301
9. Install the motor wedge over the gear motor. The wedge will only fit one way onto the motor.
10. After installation of the motor wedge, reassemble all the parts. Pay particular attention to the Endplate Spacer, which will be loose once you remove the Endplate.
Carefree of Colorado Left Hand Motor Wedge Installation Instruction FREESTYLE EVOLUTION
056513-002r1 5
11. Attach the end plate to the motor with the motor screws provided in the replacement kit (x2). Use a #2 Phillips head bit and a torque limiting driver. Drive the screws until they are tight.
12. Align the screw holes in the end plate and attach the new 1 inch Torx head screws to the awning case (x4). Use a T20 bit to drive the Torx head screws. Use a #2 Phillips head bit to drive in the longer screw in the endplate spacer. In some cases, the 1 inch Torx screw may not bite into the aluminum, especially at the location that uses the Endplate spacer. It is acceptable to reuse one of the longer Phillips head screws in that location if necessary.
13. While firmly holding the partially extended lead rail, carefully remove the spring arm ties previously installed. Allow the lead rail to extend until the fabric is taut. If using zip ties, carefully cut the zip ties. The lead rail should not move.
14. Attach the End Cap and screw.
15. Connect to the awning via the Carefree Connects App, and follow the Firmware Update procedure in user manual 056513-003.
16. Using the awning switches, verify function of the awning.
a. Extend the awning fully. Note that the fabric is taut.
b. Retract the awning fully. Make sure that the lead rail sits into the case. Small gaps are acceptable but should be no bigger than 1/2″.
c. Extend the awning and shake the leadrail. The awning should close automatically.
17. Follow all OEM instructions to validate that ignition lockout testing is functioning.
Carefree of Colorado BT12
056513-003r1 1
SERVICE MANUAL
CAREFREE CONNECTS FIRMWARE
UPDATE
FOR CAREFREE 12V MOTORIZED AWNINGS EQUIPPED WITH
RV CAREFREE’S BT12 WIRELESS AWNING CONTROL SYSTEM
Read this manual before installing or using this product. Failure to follow the
instructions and safety precautions in this manual can result in personal injury and/or
cause the product to not operate properly. This instruction is limited to BT12 Firmware
updates and verification of BTMotion connectivity. For more information on Carefree
Connects mobile app, please reference the Carefree Connects Mobile App Manual pn
070029-201.
Carefree of Colorado www.carefreeofcolorado.com a Scott Fetzer company
BT12 Carefree Connects Firmware Update Carefree of Colorado
2 056513-002r1
DOWNLOAD
Download the latest version of the Carefree Connects App from the Apple App store or the Google Play store.
FIRMWARE VERIFICATION
Open the Carefree Connects mobile app.
Pair then click on the awning you want to update (it might have a different name).
Click on cogwheel in upper corner.
Scroll down on settings.
Scroll to the bottom, click on “Check for updates”.
If the Firmware is up to date, click ok and test the app below.
If the Firmware needs updating, click “Ok”.
After clicking “Ok”, you will see several screens appear and a download status.
BTA052 (a-j)
Carefree of Colorado BT12
056513-003r1 3
TEST THE APP
Once the download is complete, you must force-close the app and reopen.
Reopen the app, reconnect to the awning, click on the cogwheel, and scroll to the About screen. Verify FW version 3.1.10 is loaded. Then proceed to test the app.
Verify the wind sensor is working – This wind symbol should be present, and White. If it is Black or missing, you must reconnect the wind sensor. Please refer to 070029-201 Carefree Connects Mobile app for pairing instructions.
Paired wind sensor not communicating.
Un-Paired wind sensor
Extend and Retract the connected awning – These buttons should fully extend and fully retract the awning
If the BT12 control module has the LED chip, this symbol will appear – Cycle the LED lights on/off, and verify that dimming controls are working.
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IMPORTANT SAFETY RECALL
Page 1 of 2
February 2024
Pursuant to USC49CFR §577.13 – Notification to Dealerships and Distributors – Paragraph B
“It is a violation of Federal Law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by the notification under a sale or lease until the defect or noncompliance is remedied. Substantial civil penalties apply to violations of this law.”
–Forest River motorized and towable products are contained in this section-
CANADA: Pursuant to the Canadian Motor Vehicle Safety Act, section 5
Companies who sell new non-complying vehicles may be in violation of the Motor Vehicle Safety Act. Substantial penalties apply to violations of this law. This notice is being sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
Forest River has decided that a safety defect exists in certain 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome recreational vehicles. Forest River is recalling the defect model(s) to ensure the safety of our future retail consumers and your dealership. Forest River apologizes for any inconvenience this action may cause your dealership; however, safety continued satisfaction and our commitment to building great products are of the utmost importance to Forest River.
The identified VIN referenced in the attached document(s).
The designated Date range of production is 03/02/2020 through 03/09/2023.
WHAT IS THE DEFECT?
Cracks may develop in the gearbox housing, causing a fracture. As a result of such fracture the awning may unintentionally extend.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
An awning that extends unintentionally while the motor home is in motion could be a distraction and/or present a road hazard to the vehicle driver or oncoming traffic, which can increase the risk of a crash.
SERVICE PROCEDURE:
Dealership Service Department procedures can be found on Dealer Connect.
PARTS AND RETURN:
Prior Authorization and Pictures of the left-hand awning cap, bracket, and motor, as well as photos of any cracks are required for the remedy. Pictures of the remedy are a condition of payment in which must be provided with a claim against the repair code(s).
DEALER REPAIR CODES: Dealer Connect
UNITED
STATES
REPAIR
CODE
DESCRIPTION
ALLOWABLE HOUR(S)
24V040
RC-042-01-00-004484
PERFORM REMEDY
1.0 HRS
HELPFUL CONTACT INFORMATION:
CONTACT
PHONE
CUSTOMER SERVICE
(574) 825-6319
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
PO Box 30
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 24V040
FR ID: 225-1723
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IMPORTANT SAFETY RECALL
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The Recall shall be considered the utmost priority to remedy the 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome in question. The retail consumer shall not be charged any amount of monies for remedy to their 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome listed under this Recall.
If your dealership has already performed the remedy to 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s). If the remedy needs to be performed on an out of warranty 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome in which the VIN falls under as stated in the identified VIN listing, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s).
Notice:
In no manner shall a Forest River Product Owner or Coachmen Product Owner be charged any fee(s) for scheduling, conduction or completion of the recall. Additionally, all dealership(s) that are Forest River and/or Coachmen dealership(s) are Federally Mandated to perform the recall once presented with this recall whether by the Owner or Dealership receipt of this letter, without denial of service to the Owner. Lastly, denial of a remedy for this recall is a Federal Violation punishable by law resulting substantial fines and/or civil penalties.
Federal Regulation requires that any lessor receiving this Recall must forward a copy of this notice to the lessee within ten days. If your dealership no longer owns this vehicle, please inform the Warranty Manager of the product listed above of the change of ownership.
Sincerely,
Forest River, Inc.
Office of Corporate Compliance
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Corporate Compliance PO Box 30 Middlebury, In 46540
February 2024
This Notice applies to your vehicle VIN listed above.
Dear Forest River Customer:
This notice is sent to you 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 2020-2023 Galleria and 2021-2023 Beyond and Nova Class B Motorhome recreational vehicles.
WHAT IS THE DEFECT?
Cracks may develop in the gearbox housing, causing a fracture. As a result of such fracture the awning may unintentionally extend.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
An awning that extends unintentionally while the motor home is in motion could be a distraction and/or present a road hazard to the vehicle driver or oncoming traffic, which can 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. 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. The remedy will include installation of additional material (which the Company refers to as a “wedge”) intended to support the internal components inside certain Freestyle left-handed gearbox motor housing assemblies. If the motor needs replaced, the newly designed motor with the wedge will be installed. 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 1.0 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:
CRV Class B
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury IN, 46540
NHTSA RECALL: 24V040
FOREST RIVER ID: 225-1723
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WHAT IF YOU NO LONGER OWN THIS VEHICLE?
If you no longer own this vehicle and have the address for the current owner, please forward this letter to the new owner within 10 working days after the day in which the notice is received. You have received this letter because government regulations require that a notification is sent to the last known owner of record. Our records indicate that you are the current owner.
PLEASE NOTE: FEDERAL LAW REQUIRES THAT ANY VEHICLE LESSOR RECEIVING THIS RECALL NOTICE MUST FORWARD A COPY OF THIS NOTICE TO THE LESSEE WITHIN TEN DAYS.
MAY FOREST RIVER ASSIST YOU FURTHER?
If you have difficulties getting your vehicle repaired, please contact your Forest River Representative listed below:
CONTACT
PHONE
CUSTOMER SERVICE
(574) 825-6319
If after contacting your dealer and/or our customer care helpline, should you have additional questions in regard to this recall, you may contact:
For US Owners Please Contact:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave, S.E.
Washington, D.C. 20590
Or you may call the toll free Vehicle Safety Hotline at 1-888-327-4236 or (TTY: 1-800-424-9153).
Or visit www.safercar.gov and search;
Recall ID: 24V040
Sincerely,
Forest River Inc.
Office of Corporate Compliance
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SEOCONTENT-END