Recall WAY-101 – Frame Rail Hitch Extensions May Fail – 2017-2022 Tiffin Wayfarer Motorhomes

August 5, 2021 NHTSA CAMPAIGN NUMBER: 21V610000

Frame Rail Hitch Extensions May Fail

Extension failure can cause the hitch to detach from the motorhome, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V610

Manufacturer Tiffin Motorhomes, Inc.

Components TRAILER HITCHES

 

Summary

Tiffin Motorhomes, Inc. (Tiffin) is recalling certain 2017-2022 Wayfarer motorhomes. Continuous stress on the frame rail hitch extensions may cause them to fail.

 

Remedy

Dealers will inspect and replace the hitch and reinforce the frame rail extension, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Tiffin customer service at 1-256-356-8661. Tiffin’s number for this recall is WAY-101.

 

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.

 

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Recall Inspection and Repair Instructions

NHTSA Recall #: 21V-610

Tiffin Motorhomes Recall #: WAY-101

Models Involved: 2017, 2018, 2019, 2020, 2021 & 2022 Wayfarer Motorhomes, all floorplans.

 

Tools Needed:

¾” OR 19MM BOX END WRENCH

¾” OR 19MM DEEP WELL SOCKET

RATCHET

PNEUMATIC OR ELECTRIC IMPACT GUN

HAMMER/MALLET

PRY BAR

FLOOR JACK

JACK STANDS

HYDRAULIC LIFT IF AVAILABLE

 

Parts Needed:

24FW, 24QW, 24TW, 25QW, 25RW, 25SW,

25TW floorplans require the following parts:

2 of 5125064, liner gussets

1 of 5125485, gusseted hitch

8, 2” grade 8 hex bolts and nuts

 

FLAT RATE CODES AND TIMES

When filing the warranty claim for payment please use the following flat rate codes and times.

For 24FW, 24QW, 24TW, 25QW, 25RW, 25SW, 25TW floorplans, use code WF8803RC01, for 1.00 hour For units with damage to existing frame rail extensions please contact Winfield Service for authorization numbers and time allowed.

 

Inspection Instructions/Procedure: 

1. Inspect the condition of the existing frame rail extensions for signs of damage. If there is damage, please contact Wayfarer at 205-487-4710 for instructions and authorization.
2. If no damage is found, please proceed with the repair.

 

Repair Instructions/Procedure:

1. Remove the receiver hitch by removing the (6) grade 8 hex bolts (3 per side) from the unit’s receiver hitch using a ¾” or 19 MM socket and box end wrench. Lower the receiver hitch from chassis using a floor jack.

 

2. On some units, placement of the water tank pan favors one side of the unit. Loosening the tank pan bolts (8) 3/8” hex bolts will allow you to shift the tank and pan slightly aiding in installation of the gusset liners.

 

3. Install the gusseted extension liners part # 5125064. Start by feeding the liner gusset inside the gap between the chassis extension and tank pan.  Once started, use a mallet or sledge hammer to aid in installing the liner.  Using a 2” Grade 8 hex bolt, attach the truss to the liner and extension by feeding the bolt in from the top side and tighten the bolts to 75 ft. lbs. once installed.

 

4. Once the liners are installed, lift the new hitch, part # 5125065, into place and fasten the hitch to frame rail extensions using (6) 2” grade 8 hex bolts. Feed bolts from top to bottom of rail and tighten to 85 ft. lbs.

 

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Recall Inspection and Repair Instructions

NHTSA Recall #: 21V-610

Tiffin Motorhomes Recall #: WAY-101

Models Involved: 2017, 2018, 2019, 2020, 2021 & 2022 Wayfarer Motorhomes, all floorplans.

 

These work instructions are for the LW floor plan ONLY

 

Tools Needed:

3/4” or 19MM BOX END WRENCH

3/4” or 19MM DEEP WELL SOCKET

9/16” BOX END WRENCH

11/16” BOX END WRENCH

RATCHET

PNEUMATIC OR ELECTRIC IMPACT GUN

HAMMER/MALLET

PRY BAR

CUTTING TOOL (FOR REMOVING HARDWARE

FROM CHASSIS EXTENSIONS)

FLOOR JACK

JACK STANDS

 

Parts Needed:

25 LW floorplans will require the following parts:

1 of 5125204

2” grade 8 hex bolts and nuts kit

 

FLAT RATE CODES AND TIMES

When filing the warranty claim for payment please use the following flat rate codes and times. For the LW floor plan, please use code WF8803RC01, and please contact Winfield Service for authorization numbers and time allowed.

 

Inspection Instructions/Procedure:

1. Inspect the condition of the existing frame rail extensions for signs of damage. If there is damage, please contact Wayfarer at 205-487-4710 for instructions and authorization.
2. If no damage is found, please proceed with the repair.

 

Repair Instructions/Procedure:

1. Prep the garage area by removing the interior corner trim, 8 pieces in total, from the interior of the garage area (see photos below).

 

2. Remove the diamond tread flooring using a pry bar to start at the corners. Peel back rubber flooring from each side of the coach until the 4 flooring screws become visible.  Remove the flooring screws form the garage area completely.
3. Prep the underside of the garage area by removing the trailer hitch plug and cutting any quip ties holding the taillight harness and 7-pin harness to the rails or extensions. Route all harnesses back through the extensions allowing the area to be clear when ready for the extension removal (photo below).

 

4. For units with a rear mounted generator, remove the generator exhaust and exhaust hanger (photo below).

 

5. Remove the receiver hitch by removing the 6 grad 8 hex bolts, 3 per side, from the unit’s receiver hitch using a ¾” or 19 MM socket and box end wrench. Lower from chassis using a floor jack.
6. Remove 4 hex bolts per side holding the center cross member in place (photo below).

 

7. Remove all hydraulic jack hardware and zip tie jacks up and out of the way.

 

8. Using a ¾” wrench and driver of choice, loosen the 4 grade 8 chassis bolts per side, these bolts attach each rail to the Mercedes frame rail. Once the bolts are driven out an inch or so, cut the front 2 bolts per side and drive out towards outside of coach for removal. See photos below.

 

9. Remove the remaining 2 “chassis to extension” bolts that pass through the hydraulic jacks. While having someone hold the extension rail, drive out the remaining bolts which will allow the frame extensions to be lowered to the ground.  Removing the cross member in Step 6 will allow the extensions to be removed and lowered one at a time (photo below).

 

10. Reinstall the hydraulic leveling jacks in tandem with Step 11. IMPORTANT NOTE: Units equipped with Bigfoot leveling system will need to ensure the hydraulic foot and ram are reinstalled as a “washer” on the inside of the frame rail.

 

11. Once you have the new extensions, lift into place one side at a time. Feed the bolts in from the backside (opposite way of removal), through the hydraulic jacks and secure.  Tighten bolts to 85 ft. lbs.

 

12. Install new cross member using 4 grad 8 hex bolts per side. Tighten bolts to 85 ft. lbs.

 

13. Once the extensions are fastened to the chassis and tightened, slide the new hitch into place and attach to inside of the frame rail extensions u sing 6 grade 8 hex bolts. Tighten bolts to 85 ft. lbs.  See photos below.

 

14. Reinstall 7-pin connector and zip tie all hydraulic lines and electrical harnesses in place as needed.
15. Reinstall generator exhaust and exhaust hanger to new rail extension.
16. Finish the garage area using the removed floor screws, fasten the garage floor to the new rails. Roll rubber flooring back into place and reinstall removed corner trim to finish the garage area.

 

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IMPORTANT SAFETY RECALL NOTICE

This notice applies to your vehicle, identified by the VIN below

 

NHTSA Recall # 21V-610

Tiffin Recall # WAY-101

 

November 29, 2021

 

Wayfarer Frame Rail Extension Failure  

 

Dear Wayfarer Owner,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

Tiffin Motorhomes has decided that a defect, which relates to motor vehicle safety, exists on the following models of Wayfarer motorhomes: 2017, 2018, 2019, 2020, 2021 & 2022 Wayfarer Motorhomes, all floorplans.

 

This is the second of two letters owners will receive regarding this recall. This letter is to inform owners that Wayfarer now has a remedy available to complete this recall regarding the hitch on your Wayfarer motorhome. As previously notified, the hitch on the Wayfarer Motorhomes may become loose from the frame of the motorhome.  We continue to warn that OWNERS MUST NOT TOW OR USE THE HITCH UNDER ANY CIRCUMSTANCE UNTIL THE RECALL REPAIR HAS BEEN COMPLETED.   The area of the hitch attachment to the frame on the Wayfarer brand of motorhomes needs to be reinforced.  If the area of the attachment of the hitch to the frame is not reinforced, the repeated stress on the frame could cause it to break which would cause the hitch to become loose and possibly break away from the motorhome.  If the hitch were to become loose or break away, this could cause a crash which could lead to an injury.

 

Please arrange to take your motorhome to a reputable service center OR dealer of your choice to have the correction completed.  Please allow up 1 hour to have this repair completed, however if preexisting damage to the frame rail extensions are found, please be aware that more time may be needed depending on the repair.  This work will be completed at no charge to you, the owner.

Once your appointment has been made, the dealer or service center you choose can contact Wayfarer

Motorhomes to order parts, obtain working instructions and billing information.  They can contact Wayfarer by phone at 205-487-4710 or by email at winfieldservice@tiffinmotorhomes.com.

 

PLEASE NOTE: Parts will only be shipped to service centers or dealers.  Parts will not be shipped to owners.

If owners have paid in the past for any damages due to a failure of the frame to the hitch, please submit a copy of the invoice that was paid by you, the owner, to the Wayfarer warranty department at the following address:   Wayfarer Warranty Department, 6524 State Hwy 129 North, Winfield AL 35594.  The Wayfarer Warranty Department may also be reached at 205-487-4710 or by email at winfieldservice@tiffinmotorhomes.com.

 

If you do not own the vehicle that corresponds to the identification number which appears on this Recall Notification, please return the notification to the Tiffin Recall Department with any information you can furnish that will assist us in locating the present owner.  You may email this information to recalls@tiffinmotorhomes.com.

 

If you are unable to have the defect remedied without charge and within a reasonable time after you tender the vehicle for repair, please contact the Tiffin Warranty Department, at 1-256-356-8661, 8:00 a.m. to 3:30 p.m., Central Time.  You may also wish to notify the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE, Washington DC 20590, or phone 1-888-327-4236 (TTY: 1-800-424-9153):  or go to https://www.safercar.gov.

 

Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 

We regret any inconvenience this action may cause, but feel certain you understand our interest in motor vehicle safety.

 

Tiffin Motorhomes Recall Department

 

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6 Affected Products

Vehicle

MAKE	MODEL	YEAR
TIFFIN	WAYFARER	2017-2022

 

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10 Associated Documents

Defect Notice 573 Report

RCLRPT-21V610-8374.PDF 213.357KB

 

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Recall Acknowledgement

RCAK-21V610-6867.pdf 688.612KB

 

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V610-8645.PDF 211.141KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V610-2638.pdf 199.478KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V610-3468.pdf 490.114KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V610-1765.pdf 341.286KB

 

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Recall 573 Report – Amendment 2

RCLRPT-21V610-8775.PDF 215.188KB

 

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Recall 573 Report – Amendment 1

RCLRPT-21V610-4014.PDF 215.261KB

 

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V610-6324.pdf 181.243KB

 

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V610-8477.PDF 211.242KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V610&docType=RCL

 

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