210-1734 – Control Arm Failure May Cause Loss of Control – 2023-2024 Coachmen Concord Motorhomes

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STOP SALE NOTICE
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February 9, 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.”
Pursuant to Federal Motor Vehicle Safety Act; 49 CFR Part 573.11; this notice shall serve as a formal
SAFETY RECALL – STOP SALE NOTIFICATION.
2023-2024 COACHMEN CONCORD CN321DSF CLASS C MOTORHOMES
Forest River has decided that a safety defect exists in certain 2023-2024 Coachmen Concord CN321DSF Class C 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 is issuing a Stop Sale Notice effective immediately.
Please access your Home Page on Dealer Connect to verify if your Dealership has units in stock that are subject to this recall. Enter the Service Campaign number referenced above in the “Campaign Search” field, click on the “Campaign ID Number”. Next, select “MY VINS”. Not all Dealers have units in stock that are affected by this recall.
DEFECT/NONCOMPLIANCE:
The lower control arm brackets that are part of the air ride suspension kit, may fracture the welds and fail. This condition may allow the rear axle to rotate upon braking and accelerating. Further, the axle may detach from the vehicle.
EVALUATION OF RISK:
If the lower control arm bracket(s) break, this may lead to rear axle rotation upon acceleration or braking. This condition may also allow the rear axle to detach from the vehicle. These conditions may lead to loss of vehicle control and may lead to a crash.
SERVICE PROCEDURE:
The Remedy is currently under development.
HELPFUL CONTACT INFORMATION:
CONTACT
PHONE
CUSTOMER SERVICE
(574) 825-8602
SERVICE CAMPAIGN: 001069
FR ID: 210-1734

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-095
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River, Inc. FEB 09, 2024 NHTSA Recall No. : 24V-095 Manufacturer Recall No. : 210-1734
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 : 10 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2023-2024 Forest River Inc. Coachmen Concord CN321DSF Class C Motorhomes Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by reviewing manufacturing records of deliveries of the air ride suspension components from the supplier, and when the supplier changed its supplier of the lower control arm bracket.
2023 CONCORD CNC321DSF 6
2024 CONCORD CNC321DSF 4
Grand Total 10 Production Dates : MAY 11, 2023 – JAN 05, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The lower control arm brackets that are part of the air ride suspension kit, may fracture the welds and fail. This condition may allow the rear axle to rotate upon braking and accelerating. Further, the axle may detach from the vehicle.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the lower control arm bracket(s) break, this may lead to rear axle rotation upon acceleration or braking. This condition may also allow the rear axle to detach from the vehicle. These conditions may lead to loss of vehicle control and may lead to a crash.
Description of the Cause : Vendor Manufacturing Defect
Identification of Any Warning
that can Occur :
None Part 573 Safety Recall Report 24V-095 Page 2 Involved Components : Component Name 1 : Affected Lower Control Arm Mount Component Description : Affected Lower Control Arm Mount Component Part Number : N/A Supplier Identification : Component Manufacturer
Name : Autoflex Suspensions Address : 1070 Gorham St.
Thunder Bay, ON Foreign States P7B 5X5
Country : Canada Chronology :
On January 23, 2024, the manufacturing plant was relocating a vehicle from one location to another in its holding yard (at the same manufacturing plant) when the driver noticed that the rear end wasn’t behaving correctly when applying the brakes. Upon inspection, the driver and manufacturing personal found that the cause from broken lower control arms (passenger and driver side). The week of January 29, 2024, the manufacturing plant began working with the supplier to try to identify the failure. Additionally, the warranty group researched if there were any failures in the field and found none. On February 2, 2024, Forest River’s Office of Corporate Compliance (“OCC”) was asked to attend a meeting with the manufacturing plant and the supplier. OCC opened a research item into the concern. On February 9, 2024, Forest River’s Corporate Recall Committee voted to Recall. A Stop Sale Notice will be issued immediately following this recalls’ filing. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-095
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The information contained in this report was submitted pursuant to 49 CFR §573
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 or Service Center will need to perform the remedy. The lower control arm mount will be replaced.
What is the Forest River Customer Service Phone Number? (574) 825-8602 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 Class C Forest River, Inc.
Attn: WARRANTY MANAGER PO Box 30
Middlebury, IN 46540
How Remedy Component Differs from Recalled Component :
NR
Affected Lower Control Arm Mount: TBD Replacement Lower Control Arm Mount: TBD Autoflex Suspensions – (807) 623-0590
1070 Gorham St.
Thunder Bay, ON P7B 5X5 – Canada”
Identify How/When Recall Condition was Corrected in Production :
The week of February 5, 2024, the supplier and manufacturing plant began installing a revised lower control arm bracket to vehicles in stock and in 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 20, 2024 – MAR 20, 2024
Planned Owner Notification Date : MAR 20, 2024 – MAR 20, 2024
* NR – Not Reported

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RECALL 24V095 / 2024-078 REMEDY INSTRUCTIONS
Make(s): CONCORD
Model(s): CNC321DSF
Model Year(s): 2023 – 2024
Concern:
The lower control arm brackets that are part
of the air ride suspension kit, may fracture
the welds and fail.
Repair Code: RC-005-01-00-004488
Allotted Time: 3.00 HRS.
Inspection Code: N/A
Allotted Time: N/A
Photo(s) Required: NO
Prior Authorization Required: YES
Part(s) Kit Number: F007-01424
Part(s) Return: NO, FIELD DESTROY
Turn off LP Gas at LPG Tank(s). Place vehicle in (P) Park and engage the Parking Brake. 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.
PRIOR TO ANY WORK – CONTACT:
CONTACT PHONE
CUSTOMER SERVICE (574) 825-8602
PLEASE REFERENCE THE ATTACHED REMEDY INSTRUCTIONS.
2023 – 2024 Coachmen Concord/Autoflex Suspension
1
Objective
The factory installed lower axle bracket #F007-014 may have insufficient welds and/or support creating a scenario where the rear axle can become partially disconnected from the vehicle. These brackets are to be replaced with corrected brackets #F007-01424.
Parts Needed
● 2 Lower axle brackets, Part number #F007-01424
Tools Needed
● Heavy Duty Floor Jack (To Lift at Frame)
● Standard Floor Jack (To Lift Rear Axle)*
● Heavy duty Jack Stands (6 Ton Minimum)
● ½” Drive Torque Wrench
● ½” Drive Impact Wrench
● ½” Drive sockets in the following sizes
○ 1-5/16” Socket
○ 19mm Socket*
○ 22mm Socket*
○ 15/16” Socket
● ⅜” Drive Impact Wrench
● ⅜” Drive 9/16” Socket
● 1-5/16 Wrench
● 15/16” Wrench
● Pry bar
● Hammer
*Recommended For accessibility but not required
2023 – 2024 Coachmen Concord/Autoflex Suspension
2
Procedure
Figure 1
Step 1 – Preparing Vehicle
● Place vehicle in park on flat ground and remove key from ignition.
● Block front wheels to prevent vehicle from rolling.
● Jack up the rear of the RV by lifting in front of the rear axle along frame rail and support both sides with jack stands (See Figure 1). At this time the rear wheels may not be off the ground. This is normal.
● Place jack stands under frame.(See Figure 1)
● Optional – If removing wheels, use a floor jack to lift the rear axle under the center of the differential until all rear wheels are off the ground. Remove wheels. (It is not necessary to remove the wheels but it may help with accessibility.)
Note: It is not necessary to deflate air bags. Air bags will deflate automatically when lifting under frame and allowing the rear axle to hang.
Step 2 – Disassembly
● Remove both 1-5/16 nuts from lower torque arms. Both bolts will remain in place for now.(Figure 2)
● Remove the (2) 9/16 nuts holding the lower air bag plate to the axle bracket.(Figure 3) The second nut is on the back side of the axle and can not be seen in Figure 3.
2023 – 2024 Coachmen Concord/Autoflex Suspension
3
● Using a pry bar, compress the air bags upward to gain access to the top axle bracket.(Figure 4)
● Use locking pliers or hose clamp pliers to close off the exhaust tube at the leveling valve.(Figure 5) This creates a vacuum in the air bag and will keep it compressed for easy access.
● Use a 15/16 wrench on top (Figure 6) and 15/16 socket on bottom (Figure 7) to remove the 4 bolts holding the lower axle bracket in place.
● Remove lower bracket and discard.
Step 3 – Assembly
● Install a new lower bracket onto the lower torque arm first and position the bracket under the axle. Start the 15/16 nuts onto the bolts by hand.
● Tighten the front two bolts first to 145 lb-ft and ensure the gap between the upper and lower bracket on the front side of the axle is closed.
● Once tight, move to the rear set and tighten to 145 lb-ft.
● Tighten the 1-5/16 lower torque arm bolts to 400 lb-ft. (Figure 2)
● Recheck torque on all 8 Nuts and bolts on driver and passenger side.
● Remove locking pliers from leveling valve exhaust tube.(Figure 5)
● Re-install the lower bag mount to the top axle tube bracket using the existing 9/16-inch hardware. Tighten to 45 lb-ft. (Figure 3)
● If wheels were removed, re-install, referring to lug tightening pattern and torque specs. (Figure 8)
● Remove jack stands, lower jacks, and allow air bags to air up. Test drive to ensure successful repair.
2023 – 2024 Coachmen Concord/Autoflex Suspension
4
Figure 2 – Driver Side Shown
Figure 3 – Driver Side Shown
2023 – 2024 Coachmen Concord/Autoflex Suspension
5
Figure 4 – Driver Side Shown
Figure 5 – Driver Side Shown
2023 – 2024 Coachmen Concord/Autoflex Suspension
6
Figure 6 – Driver Side Shown
Figure 7 – Driver Side Shown
2023 – 2024 Coachmen Concord/Autoflex Suspension
7
HiSpec wheels – 140 ft/lbs; identified as using the original black Ford lug nuts.
Ion wheels – 120 ft/lbs; identified as using conical chrome plated lugs
.
Figure 8 – Lug Tightening sequence

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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 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 2023-2024 Coachmen Concord CN321DSF Class C Motorhome. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
WHAT IS THE DEFECT?
The lower control arm brackets that are part of the air ride suspension kit, may fracture the welds and fail. This condition may allow the rear axle to rotate upon braking and accelerating. Further, the axle may detach from the vehicle.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
If the lower control arm bracket(s) break, this may lead to rear axle rotation upon acceleration or braking. This condition may also allow the rear axle to detach from the vehicle. These conditions may lead to loss of vehicle control and may lead to 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 lower control arm mount will be replaced. 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 3.0 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:
Coachmen Class C
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury, IN 46540
NHTSA RECALL: 24V095
FR ID: 210-1734
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