203-1757 – Distribution Panel Wire Unprotected from Battery – 2024 Forest River Aurora & Coachmen Catalina Travel Trailers

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April 5, 2024 NHTSA CAMPAIGN NUMBER: 24V254000

Distribution Panel Wire Unprotected from Battery

An unprotected wire increases the risk of a fire.

 

NHTSA Campaign Number: 24V254

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1,552

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2024 Aurora and Coachmen Catalina Travel Trailers. Improper routing may leave the distribution panel wire unprotected from the battery.

 

Remedy

Dealers will reroute the distribution panel wire to the breaker side of the mini breaker, free of charge. Owner notification letters were mailed April 26, 2024. Owners may contact Forest River Customer Service at 1-574-825-4995. Forest River’s number for this recall is 203-1757.

 

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 24V254 / 2024-214 REMEDY INSTRUCTIONS

Make(s): AURORA & CATALINA
Model(s): MANY, SEE BELOW
Model Year(s): 2024

 

Concern:

The charge line may not have over-current protection.

 

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 2024 – AURORA: BART15RBX, BART15RDX, BART16BHX, BART16RBX, BART180BHS & BART18BHS
CERTAIN 2024 – CATALINA: BCAT154RBX, BCAT154RDX, BCAT164BH, BCAT164BHX, BCAT164RB, BCAT164RBX, BCAT184BHS, BCAT184RBS, BCAT192BHS & BCAT192FQS

 

INSPECTION:

STEP 1: LOCATE THE RED “HOT” BATTERY WIRE AND TRACE IT FROM THE BATTERY AREA, PAST THE DISCONNECT, TO A SET OF MINI-BREAKERS LOCATED ON THE INSIDE OF THE A-FRAME/OR FRONT CROSS-MEMBER;

STEP 2: IF THE 6 AWG. WIRES ARE CONNECTED AS SHOWN IN FIGURE 1, MOVE ON TO THE REMEDY;

  • IF THE 6 AWG. WIRES ARE CONNECTED AS SHOWN IN FIGURE 2, CLAIM THE INSPECTION, WORK COMPLETED.

 

REMEDY:

STEP 1: LOCATE THE 6 AWG. WIRE ON THE REAR POST OF THE MINI-BREAKER. LOOSEN THE NUT AND REMOVE THE WIRE/EYELET;

STEP 2: INSTALL THE NUT BACK ONTO THE POST YOU REMOVED IT FROM AND TIGHTEN DOWN, ASSURING IT IS SECURE;

STEP 3: REMOVE THE NUT FROM THE LOWER POST ON THE REAR MINI-BREAKER;

  • REMOVE THE SMALLER WIRE/EYELET FROM THE POST;
  • INSTALL THE 6 AWG. WIRE/EYELET ONTO THE POST;
  • RE-INSTALL THE SMALLER WIRE/EYELET ONTO THE POST. ROTATE THE SMALLER WIRE WHERE THE EYELET CRIMPS DO NOT OVERLAP. IF THEY OVERLAP, THEY MAY BECOME LOOSE.
  • INSTALL THE NUT AND TIGHTEN, CLAMPING THE TWO WIRE/EYELETS TOGETHER, ENSURING PROPER SECUREMENT;
  • THE REMEDY SHOULD NOW MATCH FIGURE 2;

STEP 4: CHECK THE TWO NUTS FOR TIGHTNESS AGAIN;

STEP 5: SPRAY THE POSTS WITH BATTERY/TERMINAL PROTECTOR;

STEP 6: CHECK FOR PROPER FUNCTIONALITY OF THE 12V AND 110V SYSTEM.

 

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April 2024

This Notice applies to your vehicle VIN listed above.

Dear Forest River Customer:

This notice is 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 2024 Aurora and Catalina Travel Trailer Recreational Vehicles.

 

WHAT IS THE DEFECT?

The distribution panel is connected to the constant “12V HOT” side of the 30AMP mini breaker, which is wired directly to the battery.

 

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

The distribution panel wire may be unprotected from the battery. This condition may lead to a fire and property damage.

 

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 distribution panel wire will be moved to the breaker side (protected) of the mini breaker. 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 .20 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:

Catalina & Aurora
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury, IN 46540

 


Chronology :

On March 26, 2024, Forest River’s Office of Corporate Compliance (“OCC”) was notified that earlier in the day during a routine Corporate Standards Audit, it was discovered that the manufacturing plant was wiring the charge line from the battery to the distribution panel in production. OCC opened a research item.

On April 1, 2024, the manufacturing plant inspected their holding yard and found additional vehicles improperly wired.

On April 5, 2024, Forest Rivers Corporate Recall Committee voted to recall. A Stop Sale will be issued immediately following the filing of this recall.

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
COACHMEN CATALINA 2024
FOREST RIVER AURORA 2024

 


6 Associated Documents

Miscellaneous Document – Stop Sale Notice – 203-1757

RMISC-24V254-9948.pdf 145.175KB

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Recall Acknowledgement

RCAK-24V254-3284.pdf 645.954KB

 


Remedy Instructions and TSB

RCRIT-24V254-5764.pdf 316.643KB

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Manufacturer Notices(to Dealers,etc)

RCMN-24V254-8627.pdf 204.681KB

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Defect Notice 573 Report

RCLRPT-24V254-9040.PDF 215.491KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-24V254-3961.pdf 242.412KB

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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=24V254&docType=RCL

 


 

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