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August 10, 2021 NHTSA CAMPAIGN NUMBER: 21V623000
Fuel Heater May Overheat and Cause Fire
A fire increases the risk of injury. An engine stall can increase the risk of a crash.
NHTSA Campaign Number: 21V623
Manufacturer Forest River, Inc.
Components FUEL SYSTEM, DIESEL
Potential Number of Units Affected 4
Summary
Forest River, Inc. (Forest River) is recalling certain 2017-2018 Starcraft Allstar XL transit buses equipped with Cummins B6.7 diesel engines. The electric fuel heater within the fuel module may overheat, causing plastic in the fuel heater to melt and potentially catch fire. It may also lead to engine stalling.
Remedy
The remedy is still under development. Owner notification letters were mailed August 18, 2021. Owners may contact Forest River customer service at 1-800-348-7440. Forest River’s number for this recall is 05-1401.
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.
*** IMPORTANT SAFETY RECALL***
NHTSA Recall No. 20E-018
Cummins Campaign #C2302 Final Notice
May 28, 2021
Dear Cummins Customer:
This notice is sent to you·in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Cummins Inc. has decided that a defect which relates to motor vehicle safety exists in certain 86.7 diesel engines that were manufactured between December 16, 2015 and March 24, 2020 and equipped with fuel module option FS90301 or FS90453.
This notice applies to your engine(s) listed on the enclosed Engine/Vehicle list.
If your engine was manufactured between December 16, 2015 and February 25, 2019, you received a similar notice regarding NHTSA Recall No. 19E-020 (Cummins Safety Campaign #C2127) pertaining to your engine(s). This recall notice supersedes the prior recall notice; you must have the remedy described in this recall performed on your engine, even if your engine was remedied under the prior recall.
If your engine was manufactured between February 26, 2019 and November 5, 2019, your engine may have had repairs done according to Cummins Campaign #C2128 or ATC2278. This recall notice supersedes actions under those field actions; you must have the remedy described in this recall performed on your engine, even if your engine was remedied under those actions.
If your engine was manufactured between November 6, 2019 and March 24, 2020, this is a new action.
WHY IS A RECALL BEING CONDUCTED?
Fuel module options FS90301 and FS90453 contain an electric fuel heater. Internal electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire. It may also cause an engine stall. A fire, if undetected and uncontained, presents an increased risk of personal injury. An unexpected engine stall may increase the risk of a crash. If this condition exists, melting of the fuel heater or fuel seepage from around the fuel heater may be visible during a service event, smoke may precede or accompany a fire, or the engine may become increasingly difficult to start.
WHAT ARE WE DOING ABOUT THE PROBLEM?
Cummins has released field Safety Campaign #C2302 “B6.7 Engine-Mounted Fuel Heater Safety Campaign” to correct this condition. This campaign is currently available at Cummins Distributors and Cummins-authorized Warranty Dealers. The remedy will consist of the following: (1) disabling the fuel heater by either installing a plug in place of the fuel heater or otherwise rendering the fuel heater inoperable and (2) removing the fuse supplying electrical power to the fuel heater and installing a cover over the wire harness connector. The repair will be completed free of charge (parts and labor) and most applications will require approximately 30 minutes to complete.
This safety recall addresses the potential safety defect for your engine. However, this repair will disable the fuel heater. Cummins is currently working to determine an appropriate cold weather starting aid for customers that require it. Cummins Distributors and Dealers will be notified when a separate field action is available.
WHAT SHOULD YOU DO?
Contact the nearest Cummins Distributor or authorized Warranty Dealer to arrange to have this campaign performed on your engine. The distributor or dealer will work with you to schedule the best date to complete this repair.
In the meantime, to mitigate the safety risk, Cummins advises you to remove the fuel heater fuse as shown in Figures 1, 2 or 3 below (based on the vehicle).
Federal law requires vehicle lessors receiving this recall notice to forward a copy of this notice to the lessee within ten (10) days. Also, it is a violation of Federal law for a dealer to deliver a new vehicle or equipment covered by this recall notice under a sale or lease until the defect has been remedied.
If you previously paid to have this recall performed on your vehicle, you may be eligible for reimbursement. Please contact Cummins Care at the number below for more information.
WHO SHOULD YOU CONTACT IF YOU HAVE FURTHER QUESTIONS OR CONCERNS?
If you have questions or concerns about this recall, please contact your local Cummins Distributor or authorized warranty dealer. You may also contact Cummins Care at 1-800- CUMMINS (1-800-286-6467) or visit our website at care.cummins.com.
If you have a complaint relative to this recall, you may report it to the following:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, SE
Washington, DC 20590
You may also call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.
If you have not registered your Cummins product, please complete the enclosed registration card or register your product at https://prodreq.cummins.com/prodreq/#/webform/contactln fo.
If you are no longer the owner of the engine or vehicle listed in the table, please forward this notice to the new owner or provide the new owner’s contact information to Cummins at cummins.campaign.administ ration@cummins.com so that we can notify them of this recall.
Cummins is taking this action in the interest of safety and satisfaction with our products. We apologize for any inconvenience and thank you for your attention to this matter.
Sincerely,
Campaign Administrator Cummins Inc.
Navistar® CE Bus and 1300 FBC Fuse Removal Instructions (Reference Figure 1 below)
1. Disconnect vehicle
2. Locate red 50 Amp or green 30 Amp Maxi Fuse on under hood fuse
3. Remove fuse cap and discard red or green Maxi
4. Reinstall fuse Do not replace fuse.
5. Reconnect vehicle
Figure 1 – Location of Fuse on Navistar® CE Bus and 1300 FBC.
Navistar® MV, HV and TC Commercial Bus (some DuraStar (4300)/WorkStar (7300) Fuse Removal Instructions (Reference Figure 2 below)
1. Disconnect vehicle
2. Remove 30 or 40 amp fuse located at 2C
3. Reconnect vehicle battery.
Figure 2 – Location of 30A or 40A Fuse on Navistar® MV/HV/TC.
Navistar® DuraStar (4300) / WorkStar (7300) / HC Commercial Bus Fuse Removal Instructions (Reference Figure 3 below)
1. Disconnect vehicle
2. Remove Power Distribution Module (PDM) cover, located under the hood on the driver side of the vehicle.
3. Remove fuse located at cavity 2C.
4. Reconnect vehicle
Figure 3 – Location of Fuse on Navistar® DuraStar (4300) / WorkStar (7300) / HC Commercial Bus
Dear Forest River Customer:
This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This notice is also sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Forest River – Office of Corporate Compliance (“OCC”) has decided that a defect, which relates to the motor vehicle safety, exists in certain 20172018 Starcraft Allstar XL Transit Buses. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
WHAT IS THE DEFECT/NONCOMPLIANCE?
As stated by the defect notice received by Cummins, Inc. per recall 20E018: Excessive electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire. It may also cause an engine stall.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
As stated by the defect notice received by Cummins, Inc. per recall 20E018: A fire, if undetected and uncontained, presents an increased risk of personal injury. An unexpected engine stall may increase the risk of a crash.
WHAT IS CUMMINS GOING TO DO?
Cummins is developing the remedy program. The remedy program is expected to address three distinct subsets of engines that comprise the total population identified. A recall-specific reimbursement plan will be provided in the Recall Portal for those units not covered by the manufacturer’s limited warranty.
WHAT SHOULD YOU DO?
Cummins Care at 1-800-CUMMINS (1-800-286-6467), or visit our website at care.cummins.com
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:
Starcraft Bus (5A)
2367 Century Drive
Goshen, IN 46528
Fuel Heater May Overheat and Cause Fire – Cummins B6.7 Diesel Engines
Fuel Heater May Overheat and Cause Fire – Cummins B6.7 Diesel Engines
SEOCONTENT-START
IMPORTANT SAFETY RECALL
Page 1 of 2
August 2021
This Notice applies to your vehicle VIN listed above.
Dear Forest River Customer:
This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This notice is also sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Forest River – Office of Corporate Compliance (“OCC”) has decided that a defect, which relates to the motor vehicle safety, exists in certain 2017-2018 Starcraft Allstar XL Transit Buses. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
WHAT IS THE DEFECT/NONCOMPLIANCE?
As stated by the defect notice received by Cummins, Inc. per recall 20E018: Excessive electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire. It may also cause an engine stall.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
As stated by the defect notice received by Cummins, Inc. per recall 20E018: A fire, if undetected and uncontained, presents an increased risk of personal injury. An unexpected engine stall may increase the risk of a crash.
WHAT IS CUMMINS GOING TO DO?
Cummins is developing the remedy program. The remedy program is expected to address three distinct subsets of engines that comprise the total population identified. A recall-specific reimbursement plan will be provided in the Recall Portal for those units not covered by the manufacturer’s limited warranty.
WHAT SHOULD YOU DO?
Cummins Care at 1-800-CUMMINS (1-800-286-6467), or visit our website at care.cummins.com
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:
Starcraft Bus (5A)
2367 Century Drive
Goshen, IN 46528
What if you no longer own this vehicle?
If you no longer own this vehicle and have the address for the current owner, please forward this letter to the new owner within 10 working days after the day in which the notice is received. You have received this letter because government regulations require that a notification is sent to the last known owner of record. Our records indicate that you are the current owner.
PLEASE NOTE: FEDERAL LAW REQUIRES THAT ANY VEHICLE LESSOR RECEIVING THIS RECALL NOTICE MUST FORWARD A COPY OF THIS NOTICE TO THE LESSEE WITHIN TEN DAYS.
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
BUILDING 11
423 N MAIN ST
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 21V623
CANADA RECALL: N/A
FR ID: 05-1401
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Page 2 of 2
MAY FOREST RIVER ASSIST YOU FURTHER?
If you have difficulties getting your vehicle repaired, please contact your Forest River Representative listed below:
CONTACT
PHONE
CUSTOMER SERVICE
(800) 348-7440
If you are still having difficulty getting your vehicle repaired in a reasonable amount of time or without charge, you may write to the following address:
For US Owners Please Contact:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave, S.E.
Washington, D.C. 20590
Or you may call the toll free Vehicle Safety Hotline at 1-888-327-4236 or (TTY: 1-800-424-9153).
Or visit www.safercar.gov and search;
Recall ID: 21V623**************************************************************************************************************IMPORTANT SAFETY RECALL
Page 1 of 2
August 2021
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.”
–Forest River motorized and towable products are contained in this section-
CANADA: Pursuant to the Canadian Motor Vehicle Safety Act, section 5
Companies who sell new non-complying vehicles may be in violation of the Motor Vehicle Safety Act. Substantial penalties apply to violations of this law. This notice is being sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
Forest River – Office of Corporate Compliance (“OCC”) has decided that a safety defect exists in certain 2017-2018 Starcraft Allstar XL Transit Buses. Forest River is recalling the defect model(s) to ensure the safety of our future retail consumers and your dealership. Forest River apologizes for any inconvenience this action may cause your dealership; however, safety continued satisfaction and our commitment to building great products are of the utmost importance to Forest River.
The identified VIN referenced in the attached document(s).
The designated Date range of production is 8/25/2017 through 8/20/2018
DEFECT/NONCOMPLIANCE:
As stated by the defect notice received by Cummins, Inc. per recall 20E018: Excessive electrical heating within the fuel heater may create sufficient heat inside the fuel heater to cause plastic in the fuel heater to melt and potentially catch fire. It may also cause an engine stall.
EVALUATION OF RISK:
As stated by the defect notice received by Cummins, Inc. per recall 20E018: A fire, if undetected and uncontained, presents an increased risk of personal injury. An unexpected engine stall may increase the risk of a crash.
SERVICE PROCEDURE:
Cummins is developing the remedy program. The remedy program is expected to address three distinct subsets of
engines that comprise the total population identified. A recall-specific reimbursement plan will be provided in the Recall Portal for those units not covered by the manufacturer’s limited warranty. What is Cumming Inc. contact information? Cummins Care at 1-800-CUMMINS (1-800-286-6467), or visit our website at care.cummins.com
HELPFUL CONTACT INFORMATION:
CONTACT
PHONE
CUMMINS
(800) CUMMINS
STARCRAFT CUSTOMER SERVICE
(800) 348-7440
The Recall shall be considered the utmost priority to remedy the 2017-2018 Starcraft Allstar XL Transit Buses in question. The retail consumer shall not be charged any amount of monies for remedy to their 2017-2018 Starcraft Allstar XL Transit Buses listed under this Recall.
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
BUILDING 11
423 N MAIN ST
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 21V623
CANADA RECALL: N/A
FR ID: 05-1401
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Page 2 of 2
If your dealership has already performed the remedy to 2017-2018 Starcraft Allstar XL Transit Buses, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s). If the remedy needs to be performed on an out of warranty 2017-2018 Starcraft Allstar XL Transit Buses in which the VIN falls under as stated in the identified VIN listing, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s).
Notice:
In no manner shall a Forest River Product Owner or Coachmen Product Owner be charged any fee(s) for scheduling, conduction or completion of the recall. Additionally, all dealership(s) that are Forest River and/or Coachmen dealership(s) are Federally Mandated to perform the recall once presented with this recall whether by the Owner or Dealership receipt of this letter, without denial of service to the Owner. Lastly, denial of a remedy for this recall is a Federal Violation punishable by law resulting substantial fines and/or civil penalties.
Federal Regulation requires that any lessor receiving this Recall must forward a copy of this notice to the lessee within ten days. If your dealership no longer owns this vehicle, please inform the Warranty Manager of the product listed above of the change of ownership.***************************************************************************************************************
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*
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*
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*
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2 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| STARCRAFT BUS | ALLSTAR XL | 2017-2018 |
9 Associated Documents
Recall Quarterly Report #1, 2021-3
RCLQRT-21V623-6223.PDF 211.129KB
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Recall Acknowledgement
RCAK-21V623-3030.pdf 645.716KB
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Defect Notice 573 Report
RCLRPT-21V623-7069.PDF 214.137KB
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Manufacturer Notices(to Dealers,etc)
RCMN-21V623-7430.pdf 217.725KB
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Remedy Instructions and TSB
RCRIT-21V623-3752.pdf 1922.208KB
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ISSUED Owner Notification Letter(Part 577)
RCONL-21V623-9528.pdf 207.92KB
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Recall 573 Report – Amendment 1
RCLRPT-21V623-2879.PDF 214.937KB
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Recall Quarterly Report #2, 2021-4
RCLQRT-21V623-6413.PDF 211.228KB
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Recall Quarterly Report #3, 2022-1
RCLQRT-21V623-6072.PDF 211.311KB
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Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V623&docType=RCL
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