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

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February 9, 2024 NHTSA CAMPAIGN NUMBER: 24V095000

Control Arm Failure May Cause Loss of Control

A loss of vehicle control increases the risk of a crash.

 

NHTSA Campaign Number: 24V095

Manufacturer Forest River, Inc.

Components SUSPENSION

Potential Number of Units Affected 10

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2023-2024 Coachmen Concord motorhomes. The lower control arm bracket may fail and cause the axle to rotate or detach, resulting in a loss of vehicle control.

 

Remedy

Dealers will replace the lower control arm mount, free of charge. Owner notification letters were mailed February 19, 2024. Owners may contact Forest River customer service at 1-574-825-8602. Forest River’s number for this recall is 210-1734.

 

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.safercar.gov.

 


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.

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.

 

2023 – 2024 Coachmen Concord/Autoflex Suspension

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

*Recommended For accessibility but not required

 

Procedure 

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.
  • 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.

 

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

 

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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

 


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.

 


2 Affected Products

Vehicle

MAKE MODEL YEAR
COACHMEN CONCORD 2023-2024

 


6 Associated Documents

Recall 573 Report

RCLRPT-24V095-7815.PDF 214.714KB

 


Miscellaneous Document – Stop Sale Notice – 210-1734

RMISC-24V095-8911.pdf 120.025KB

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Recall Acknowledgement

RCAK-24V095-9785.pdf 645.977KB

 


Remedy Instructions and TSB

RCRIT-24V095-7398.pdf 2554.737KB

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Manufacturer Notices(to Dealers,etc)

RCMN-24V095-7202.pdf 181.668KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-24V095-4718.pdf 241.72KB

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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=24V095&docType=RCL

 


 

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Last update on 2024-06-19 / Affiliate links / Images from Amazon Product Advertising API

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