51-1488 – Coupler Improperly Welded – 2022 East to West Della Terra, Silver Lake, Forest River Vibe, & XLR Boost Toy Hauler Travel Trailers

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March 11, 2022 NHTSA CAMPAIGN NUMBER: 22V143000

Coupler Improperly Welded

Trailer separation from a tow vehicle can increase the risk of a crash.

 

NHTSA Campaign Number: 22V143

Manufacturer Forest River, Inc.

Components EQUIPMENT, TRAILER HITCHES

Potential Number of Units Affected 645

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2022 East to West Della Terra, Silver Lake, Vibe, and XLR Boost Toy Hauler travel trailers. The coupler was improperly welded, which may cause the trailer to separate from the tow vehicle.

 

Remedy

Dealers will inspect and replace the coupler as necessary, free of charge. Owner notification letters were mailed March 31, 2022. Owners may contact the following customer service numbers: Forest River 1-574-825-4995; East to West Della Terra & Silver Lake 1-574-264-6664; Vibe 1-574-296-2084; and XLR 1-574-642-0432. Forest River’s number for this recall is 51-1488.

 

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 22V143 / 2022-109 REMEDY INSTRUCTIONS

Make(s): MANY, SEE BELOW
Model(s): MANY, SEE BELOW
Model Year(s): 2022
Repair Code: RC-004-01-00-004165
Allotted Time: 1.50 HRS.
Inspection Code: RC-004-05-00-004164
Allotted Time: .20 HRS
Concern:
The 2 5/16” coupler may have components only spot-welded to it by the coupler manufacturer. This condition may lead to trailer separation from the tow vehicle.
Photo(s) Required: YES, BEFORE & AFTER
Prior Authorization Required: NO
Part(s) Kit Number: 21700033
Part(s) Return: NO

 

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 MODELS:

Della Terra – DET200RD & DET250BH
Silver Lake – SKT25KRB & SKT27KNS
VIBE – VBT25RK, VBT26BH, VBT26RK, VBT28BH, VBT28RB, VBT28RL, VBT31ML, VBT32BH & VBT34BH
XLR Boost Toy Hauler – XLT21QBS-79B & XLT25LRLE-79

 

INSPECTION/REMEDY INSTRUCTIONS ARE LOCATED IN DEALER CONNECT!

STEP 1: PLEASE FOLLOW THE INSPECTION, AND, IF REQUIRED, THE REMEDY INSTRUCTIONS FROM NORCO
INDUSTRIES.

NOTE: IF A REPLACEMENT COUPLER IS REQUIRED, TAKE PHOTOS OF THE COUPLER AND SUBMIT YOUR CLAIM ON DEALER CONNECT. PLACE THE PARTS ORDER VIA DEALER CONNECT AS WELL. FOREST RIVER/COACHMEN WILL FACILITATE THE ORDER THROUGH NORCO TO BE SHIPPED DIRECTLY TO YOUR DEALERSHIP/SERVICE CENTER.

CLAIM THE INSPECTION OR REPAIR CODE THROUGH FOREST RIVERS’ DEALERCONNECT.

 

NORCO INDUSTRIES APPROVED INSPECTION PROCEDURE

STEP 1: VISUAL INSPECTION

1) Inspection location: Bottom side of coupler located at the front end of the a-frame.

2) Underneath the coupler, use a flashlight to inspect the welds at each side of the bottom coupler plate.

a. To Pass Inspection: A weld bead should run along each side of the plate.

b. To Fail Inspection: A weld bead will not run along the side of the plate and there will only be tack welds

 

NORCO INDUSTRIES APPROVED REPAIR PROCEDURE

STEP 2: REPAIR IF VISUAL INSPECTION FAILS

1) In a circumstance that the coupler is only tack welded on the underneath plate, the coupler will need to be replaced by a qualified welder.

2) Safely support the front of the RV with jack stands and remove the tongue jack.

3) Carefully cut through the perimeter welds of the coupler allowing the defective coupler to be removed. Use caution not to damage the draw tubes when cutting through the welds.

4) Using a grinder, remove any excess weld from the draw tubes once the coupler has been removed.

5) Prep the replacement coupler by removing the paint from the weld locations.

6) Weld the replacement coupler in place just as the original was welded.

7) Paint raw steel areas.

 


This notice is sent to you in accordance with the requirements Motor Vehicle Safety Act. 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 2022 Della Terra, Silver Lake, Vibe and XLR Boost Toy Hauler Travel Trailer Recreational Vehicles. 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?

The hitch coupler was not properly welded by the coupler vendor.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
If the coupler fails and the travel trailer separates from the tow vehicle, this could lead to a crash, injury and/or 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. The remedy for this recall will be to inspect the welds on the coupler and if found to be incorrect the coupler will be replaced. 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 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 1.50 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:

East to West Della Terra & Silver Lake
Forest River, Inc.
Attn: WARRANTY MANAGER
3000 CR 6 West
Elkhart, IN 46514

Vibe
Forest River, Inc.
Attn: WARRANTY MANAGER
411 CR 15
Elkhart, IN 46516

XLR
Forest River, Inc.
Attn: WARRANTY MANAGER
2421 Century Dr
Goshen, IN 46528

 


Chronology :

On March 4, 2022, Forest River’s Office of Corporate Compliance (“OCC”) received a notice from NORCO Industries, a chassis supplier. NORCO provided dates in which chassis were delivered to certain manufacturing plants.

According to the notice received from NORCO: “Norco Industries contacted Pacific Trailer Product Inc. on October 13th of 2021 upon identifying couplers that did not pass inspection. We immediately organized a sorting and inspection process for raw material inventory, inventory in WIP and inventory in the yard for completed frames. Although defective couplers were found in raw material, zero defects were found in WIP or completed frames. Norco has continued to visually inspect coupler welds since the inception on October 13, 2021

On 02/10/2022, Norco Industries received notification that Pacific Trailer Product Inc. decided that a defect, which relates to vehicle safety, exists in certain batches of CA-5400-O and CA-5400-B couplers. Our supplier sent notice in accordance with the National Traffic and Motor Vehicle Safety Act and released a Safety Recall, 22E-003V.

As a result of Operations’ immediate attention and action, the scope of the affected product for our customers was drastically reduced. Norco frames produced between 09/09/2021 and 10/13/2021, may have been assembled with couplers related to the suspect batches provided by Pacific Trailer Product Inc. This window starts the first day a suspect coupler could have been assembled into a frame and ends with the beginning of our 100% inspection.”

On March 11, 2022, Forest Rivers Corporate Recall Committee voted to recall

 


22E003 – Coupler Improperly Welded – Pacific Trailer RAM A Frame 2 5/16″ Couplers

 

22E003 – Coupler Improperly Welded – Pacific Trailer RAM A Frame 2 5/16″ Couplers

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
EAST TO WEST DELLA TERRA 2022
EAST TO WEST SILVER LAKE 2022
FOREST RIVER VIBE 2022
FOREST RIVER XLR TOYHAULER 2022

 


10 Associated Documents

Recall Acknowledgement

RCAK-22V143-8284.pdf 645.875KB

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Defect Notice 573 Report

RCLRPT-22V143-3080.PDF 217.463KB

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Remedy Instructions and TSB

RCRIT-22V143-6980.pdf 395.107KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V143-0038.pdf 175.315KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V143-7937.pdf 204.645KB

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Miscellaneous Document – Notification from Norco

RMISC-22V143-3703.pdf 943.889KB

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Recall Quarterly Report #1, 2022-1

RCLQRT-22V143-7061.PDF 211.123KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-22V143-1693.PDF 211.225KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-22V143-3857.PDF 211.307KB

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Recall Quarterly Report #4, 2022-4

RCLQRT-22V143-2674.PDF 211.418KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V143&docType=RCL

 


 

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