22E018 – Coupler Improperly Welded – Norco Frames Model CA-5400

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March 11, 2022 NHTSA CAMPAIGN NUMBER: 22E018000

Coupler Improperly Welded

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

 

NHTSA Campaign Number: 22E018

Manufacturer Norco Industries Inc.

Components TRAILER HITCHES, EQUIPMENT

Potential Number of Units Affected 3,587

 

Summary

Norco Industries Inc. (Norco) is recalling certain Norco Frames equipped with Model CA-5400 couplers. The coupler was improperly welded, which may cause a trailer to separate from the tow vehicle.

 

Remedy

Dealers will inspect the welds, and replace the coupler if necessary, free of charge. The manufacturer has not yet provided a schedule for recall notification. Owners may contact Norco customer service at 1-574-262-3400.

 

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

This notice applies to some Norco Industries Inc. (Norco) Frames equipped with Model CA-5400 couplers.

NHTSA Recall Number: 22E-018

 

March 15, 2022

 

Keith Fisher
East to West
423 N. Main Street
Middlebury, IN 46540

 

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

 

Norco Industries has decided that a defect, which relates to vehicle safety, exists in certain Norco Frames. This notice applies to the subject of frames shipped from Norco Industries between 09/09/2021 and 10/13/2021. Your company may have been notified of this issue this month and may have conducted the research already.

 

WHAT IS THE PROBLEM WITH THE FRAMES?

Part: Frames assembled with CA-5400 Couplers
Malfunction: Break
Condition: Incomplete weld on bottom plate of coupler
Precaution: Visual inspection bottom side of coupler
Safety Risk: The welds on the bottom side of the coupler could break causing possible disconnect with tow vehicle.

 

Norco Industries will pay for inspection and replacement of any defective couplers at no cost to you.

 

WHAT SHOULD YOU DO?

Inspect products built with the Norco Frames specified in the time frame above using the attached Pacific Trailer Products,

Inc. Coupler Recall 22E-003V Remedy Instructions. If any couplers are found to have “spot welds” as shown on the Remedy Instructions. Remedy/Replacement couplers are available immediately.

 

WHO SHOULD YOU CONTACT WITH FURTHER QUESTIONS OR CONCERNS?

If you should have questions regarding this recall, please contact Norco Industries Technical Support at 1 (877) 557-7788. If you fail to obtain a satisfactory remedy to this defect without charge, or within a reasonable amount of time, you may submit a written complaint to:

Administrator
National Highway Traffic Safety Administration
1200 New Jersey AVE 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

 

WHAT IS YOU HAVE ALREADY CONDUCTED THE INSPECTION OR REPLACED THE COUPLER?

You may be eligible to receive reimbursement for the cost’s incurred prior to receiving this notice.  Please submit your request to:  baltechsupport@norcoind.com

 

We apologize for any inconvenience and thank you for your attention to this safety matter. Sincerely,

 

Norco Industries

 


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.

 

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10/13/2021

  • Norco Industries contacted Pacific Trailer Product Inc. upon identifying couplers that did not pass the standard visual inspection of raw material due to missing welds.
  • Norco Industries froze inventory and stopped all product in our shipyard.
  • Norco Industries initiated a reinspection process for raw material and inspection of inventory in WIP and inventory in the yard for completed frames.
  • The quantity of couplers that failed inspection in raw material stock/prior to assembly were 15, in one layer of the basket shipped by Pacific Trailer.
  • The quantity of couplers that failed inspection in WIP and final assembly were 0.
  • The quantity of couplers that passed inspection overall were 4400.
  • In addition to the standard inspection of raw material stock, Norco Industries added a secondary inspection prior to the welding process in production.
  • 100% containment had been achieved.

 

10/28/2021

  • Norco Industries reported an additional coupler with missing welds in raw material stock.
  • Norco Industries froze inventory and stopped all product in our shipyard as an additional precaution.
  • Norco Industries initiated a reinspection for all raw material, inventory in WIP and inventory in the yard for completed frames.
  • The quantity of couplers that failed inspection in raw material stock/prior to assembly were 23.
  • The quantity of couplers that failed inspection in WIP and final assembly were 0.
  • The quantity of couplers that passed inspection overall were 10,421.
  • 100% containment had been achieved.

 

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.
  • Norco Industries believed they were the first to report the defect during standard inspection and had 100% containment.
  • Norco validated that couplers received between 09/09/21 and 10/13/21 had been inspected by our standard inspection of raw material.

 

03/08/2022

  • Norco determined that we assembled 3,587 frames during 09/09/21 through 10/13/2021 that may have been produced with the coupler indicated in the recall notification.
  • 1,320 couplers were received by Norco from suspect lots prior to the first reported defect.
  • Although we believe we have full containment, Norco Industries did not implement the new multi-stage inspection process until the first reported defect was identified on 10/13/2021.
  • We immediately notified our affected customers of product produced between 09/09/2021 through 10/13/2021.

 


Chronology :

10/13/2021

• Norco Industries contacted Pacific Trailer Product Inc. upon identifying couplers that did not pass the standard visual inspection of raw material due to missing welds. • 100% containment had been achieved.

10/28/2021

• Norco Industries reported an additional coupler with missing welds in raw material stock.

• 100% containment had been achieved. 02/10/2022 •Norco validated that couplers received between 09/09/21 and 10/13/21 had been inspected by our standard inspection of raw material.

03/08/2022

• Although we believe we have full containment, Norco Industries did not implement the new multi-stage inspection process until the first reported defect was identified on 10/13/2021.

 


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

 


1 Affected Product

Equipment

BRAND PART NO. PRODUCTION DATES
NORCO RV HITCH TO TOW COUPLER

 


8 Associated Documents

Remedy Instructions and TSB

RCRIT-22E018-3732.pdf 176.614KB

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Defect Notice 573 Report

RCLRPT-22E018-1687.PDF 214.737KB

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Recall Acknowledgement

RCAK-22E018-1190.pdf 696.351KB

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Miscellaneous Document – Chronology

RMISC-22E018-5736.pdf 85.577KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22E018-7118.pdf 113.893KB

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Recall 573 Report – 4/4/2022

RCLRPT-22E018-9439.PDF 214.755KB

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Recall 573 Report – 4/18/2022

RCLRPT-22E018-5469.PDF 214.767KB

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Recall 573 Report – 9/27/2022

RCLRPT-22E018-9472.PDF 243.85KB

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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=22E018&docType=RCL

 


 

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