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June 12, 2024 NHTSA CAMPAIGN NUMBER: 24V429000
Insufficient Barrier Performance/FMVSS 222
An insufficient restraining barrier can increase the risk of injury in a crash.
NHTSA Campaign Number: 24V429
Manufacturer Forest River Bus, LLC
Components STRUCTURE
Potential Number of Units Affected 3,192
Summary
Forest River Bus, LLC (Forest River) is recalling certain 2013-2016 Starcraft Allstar MVP, 2016 and 2019 Allstar XL, 2016-2018 Allstar XL MVP, 2009-2010 and 2012-2018 Starcraft MFSAB/Prodigy, 2014-2016 Quest XL, 2013 and 2015-2018 Starcraft MPV/Prodigy, 2009-2010 Prodigy, 2009-2022 Quest, 2011 Quest XL school buses. The restraining barrier may not provide sufficient protection in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 222, “School Bus Passenger Seating and Crash Protection.”
Remedy
The remedy is currently under development. Owner notification letters are expected to be mailed July 10, 2024. Owners may contact Forest River customer service at 1-800-348-7440. Forest River’s number for this recall is 05-1584.
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.
05-1584 – Chronology
Forest River Bus, LLC (“FRC”), through its predecessor entity, Starcraft Bus has used the same frontal barrier design since the product was first certified in 2008. The frontal barriers used on the school buses at issue in this noncompliance report have not changed in any material respect since they were first certified.
In September 2020, NHTSA, through its third-party testing contractor Applus IDIADA KARCO Engineering, LLC (“KARCO”) evaluated the performance of a Model Year 2019 Starcraft Quest Schoolbus to the requirements of FMVSS 222, S5.2.3. That test indicated an apparent exceedance of the force/deflection curve of the passenger side restraining barrier to S5.2.3(a) and in May 2021, NHTSA initiated a formal inquiry. FRB responded to that inquiry in June 2021. As described in FRB’s response, the testing conducted by KARCO allowed for inappropriate contortion of the test apparatus because it did not have sufficient rigidity. The KARCO test apparatus did not maintain the test condition required by the regulation and in FRB’s view, the KARCO test was not conducted consistent with the FMVSS 222 test procedure. FRB retained a third-party testing facility perform additional testing of the frontal barrier in November 2021, which indicated that the frontal barrier met the requirements of S5.2.3. Videos of that testing were provided to NHTSA. The agency issued a second Information Request in March 2022 to which FRB submitted a partial response in April 2022 and submitted the remainder of the response in May 2022.
FRB met with NHTSA virtually on December 2, 2022, at NHTSA’s request. At that meeting, NHTSA stated that the frontal barrier tested by the third-party retained by FRB was a 34-inch barrier and not the same size as the 30-inch frontal barrier tested by KARCO. NHTSA took the position that the 30-inch seat barrier did not meet the FMVSS 222 frontal barrier performance requirements, and a recall was necessary.
On December 5, 2022, FRB opened a research item into the 30-inch front barrier. During the course of its investigation, FRB found that although it had requested the third-party testing facility to evaluate a 30-inch barrier, it instead evaluated a slightly larger 34-inch barrier. FRB began reviewing the production records and schedules to determine the scope of vehicles to potentially be addressed under the recall. Concurrently, FRB has arranged for additional testing and evaluation of the performance of a 30-inch barrier.
On December 16, 2022, this issue was presented to the Corporate Recall Committee, which decided to submit a Noncompliance Information Report to NHTSA with the option to file a Petition for Inconsequential Noncompliance depending on the outcome of the additional evaluation of the 30-inch frontal barrier.
On December 21, 2022 FRB submitted a Noncompliance Information Report with a notice of intent to file an Inconsequentiality Petition depending on testing results.
On January 11, 2022 FRB again retained a third-party testing facility to perform additional testing of the frontal barrier, which indicated that the frontal barrier met the requirements of S5.2.3. Videos of that testing were provided to NHTSA.
On January 17, 2022 FRB timely submitted an Inconsequentiality Petition.
On June 6, 2024, Forest River’s Office of Corporate Compliance (“OCC”) received NHTSA’s denial of the Inconsequentiality Petition and in accordance with the regulations, is now updating its Noncompliance Information Report for campaign 22V946.
43 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| FOREST RIVER BUS | STARCRAFT MFSAB/PRODIGY | 2009-2010, 2012 |
| Forest River Bus | STARCRAFT ALL STAR XL | 2016, 2019 |
| Forest River Bus | STARCRAFT ALLSTAR MPV | 2013-2016 |
| Forest River Bus | STARCRAFT ALLSTAR XL MVP | 2016-2018 |
| Forest River Bus | STARCRAFT MFSAB/PRODIGY | 2013-2018 |
| Forest River Bus | STARCRAFT MPV/PRODIGY BUS | 2013, 2015-2018 |
| STARCRAFT BUS | PRODIGY | 2009-2010 |
| STARCRAFT BUS | QUEST | 2009-2022 |
| STARCRAFT BUS | QUEST XL | 2011, 2014-2016 |
4 Associated Documents
Recall Acknowledgement
Recall 573 Report
RCLRPT-24V429-6412.PDF 218.447KB
Recall 573 Report
RCLRPT-24V429-7863.PDF 218.447KB
Miscellaneous Document – Chronology
RMISC-24V429-9886.pdf 66.528KB
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https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V429&docType=RCL
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SEOCONTENT-START
OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-429
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River Bus, LLC JUN 11, 2024 NHTSA Recall No. : 24V-429 Manufacturer Recall No. : 05-1584 Manufacturer Information :
Manufacturer Name : Forest River Bus, LLC Address : 2367 Century Drive
Goshen IN 46528
Company phone : (800) 348-7440
Population :
Number of potentially involved : 3,192 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2013-2016 Forest River Bus LLC STARCRAFT ALLSTAR MVP SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : APR 23, 2013 – JUN 06, 2016
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2016-2016 Forest River Bus LLC STARCRAFT ALLSTAR XL SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : MAY 24, 2016 – MAY 24, 2016
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-429 Page 2 Vehicle 3 : 2019-2019 Forest River Bus LLC STARCRAFT ALLSTAR XL SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : NOV 28, 2018 – NOV 28, 2018
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 4 : 2016-2018 Forest River Bus LLC STARCRAFT ALLSTAR XL MVP SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : SEP 09, 2016 – JAN 18, 2018
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 5 : 2009-2010 Forest River Bus LLC STARCRAFT MFSAB/PRODIGY SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : SEP 14, 2009 – DEC 29, 2009
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 6 : 2014-2016 Forest River Bus LLC STARCRAFT QUEST XL SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : DEC 30, 2013 – JAN 13, 2016
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-429 Page 3 Vehicle 7 : 2013-2013 Forest River Bus LLC STARCRAFT MPV/PRODIGY SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : AUG 27, 2013 – AUG 27, 2013
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 8 : 2015-2018 Forest River Bus LLC STARCRAFT MPV/PRODIGY SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : DEC 16, 2014 – NOV 03, 2017
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 9 : 2009-2010 Forest River Bus LLC STARCRAFT PRODIGY SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : APR 03, 2009 – FEB 12, 2010
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 10 : 2009-2022 Forest River Bus LLC STARCRAFT QUEST SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : FEB 23, 2010 – MAY 20, 2020
VIN Range 1 : Begin : NR End : NR Not sequential The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-429 Page 4 Vehicle 11 : 2011-2011 Forest River Bus LLC STARCRAFT QUEST XL SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : DEC 17, 2010 – DEC 23, 2010
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 12 : 2012-2018 Forest River Bus LLC STARCRAFT MFSAB/PRODIGY SCHOOL BUS Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by the school bus production schedule.
See Attached Listing by Model Year, Make and Model Production Dates : APR 23, 2012 – OCT 30, 2017
VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : The restraining barrier may not meet the requirements of FMVSS 222 “School Bus Passenger Seating and Crash Protection” barrier performance requirements. FMVSS 1 : 222 – School bus passenger seating and crash protection FMVSS 2 : NR
Description of the Safety Risk : A restraining barrier that does not meet the performance requirements may increase the potential for injury in the event of a crash. Forest River Bus is not aware of any warranty claims, complaints or other reports of any actual or alleged injuries potentially related to this issue.
Description of the Cause : NR Identification of Any Warning
that can Occur : None. Involved Components : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-429
Page 5
The information contained in this report was submitted pursuant to 49 CFR §573
Component Name 1 : 30″ – Frontal Barrier Deflector Component Description : 30″ – Frontal Barrier Deflector Component Part Number : N/A
Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR
Chronology :
SEE ATTACHED CHRONOLOGY 05-1584 – 6.10.24
Description of Remedy :
Description of Remedy Program : The remedy for this recall is under development. An amendment will be
filed once the remedy is available. How Remedy Component Differs from Recalled Component : Affected Component – 30″ – Frontal Barrier Deflector Replacement Component – TBD Identify How/When Recall Condition was Corrected in Production : Forest River ceased manufacturing all school buses in 2020. 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 : JUL 10, 2024 – JUL 10, 2024
Planned Owner Notification Date : JUL 10, 2024 – JUL 10, 2024
* NR – Not Reported
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