Recall 22-427 – Coupler Improperly Welded – 2022 Keystone Bullet, Outback, & Passport Travel Trailers

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March 28, 2022 NHTSA CAMPAIGN NUMBER: 22V195000

Coupler Improperly Welded

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

 

NHTSA Campaign Number: 22V195

Manufacturer Keystone RV Company

Components TRAILER HITCHES, EQUIPMENT

Potential Number of Units Affected 1,155

 

Summary

Keystone RV Company (Keystone) is recalling certain 2022 Bullet, Outback, and Passport travel trailers. The coupler hitch may have been welded improperly, which can cause the trailer to separate from the tow vehicle.

 

Remedy

Dealers will inspect the welds, and replace the coupler if necessary, free of charge. Owner notification letters were mailed May 3, 2022. Owners may contact Keystone customer service at 1-866-425-4369. Keystone’s number for this recall is 22-427.

 

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.

 


5/10/22

Keystone RV Company

SAFETY ADVISORY # 22-427

Norco Coupler Welds

Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that the vehicles in the recall population have a coupler hitch that may have not been welded properly. Under certain conditions during travel, the coupler welds may fail causing a separation of the trailer and tow vehicle which could lead to an increased risk of vehicle crash or personal injury.

 

Models Included:

Year Model Serial Number Ranges
2022 Bullet – All East Coast Models ND430516 – ND430755 NT430150 – NT431027
2022 Outback – All Models NB450084 – NB450833
2022 Passport – All East Coast Models ND410671 – ND410869

 

Parts Required per Inspection:

1 – KRV # 534192- Frame – Coupler – 2 5/16″ (This part requires a VIN to be ordered)

 

Tools Required:

Welder

– Grinder

 

This Safety Advisory requires a Pre-Authorization & Photograph if welds are incorrect.

Note – Check serial number on Key Express to verify the campaign is open. Some vehicles were repaired before they left Keystone.

When performing warranty or recall service, please make certain that appropriate Personal Protective Equipment (PPE) is used.

The remedy is to visually inspect the welds on the bottom of the coupler, if the bottom of the coupler is spot welded, it will need to be replaced. If welds are incorrect a picture of the bottom of the coupler is required.

 

REPAIR INSTRUCTIONS – SEE FOLLOWING NORCO INSTRUCTIONS

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.

 

EXCLUSIONS

Norco Industries shall not be liable for consequential or incidental damages of any kind in the event of a component failure caused by an improper repair and/or failure to follow the approved repair procedure.

 


Chronology :

3/4/2022 – Keystone RV was notified of Recall 22E-003V by Norco Industries.

3/7/2022 – Investigation opened into range and scope of VINs.

3/23/2022 – Investigation concluded and scope completed.

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
KEYSTONE BULLET 2022
KEYSTONE OUTBACK 2022
KEYSTONE PASSPORT 2022

 


12 Associated Documents

Recall 573 Report – 4/1/2022

RCLRPT-22V195-8819.PDF 215.548KB

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Recall Acknowledgement

RCAK-22V195-9376.pdf 651.782KB

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Defect Notice 573 Report

RCLRPT-22V195-4117.PDF 215.563KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V195-9268.pdf 144.983KB

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Remedy Instructions and TSB

RCRIT-22V195-1966.pdf 347.253KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V195-5404.pdf 144.941KB

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Manufacturer Notices(to Dealers,etc)-22-427 dealer email sent 5-3-2022

RCMN-22V195-0544.pdf 132.826KB

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Remedy Instructions and TSB

RCRIT-22V195-3244.pdf 266.511KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V195-3649.PDF 211.131KB

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Recall Quarterly Report #2, 2022-3

RCLQRT-22V195-0351.PDF 211.229KB

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ISSUED Renotification Notice

RCRN-22V195-6108.pdf 106.545KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V195-5016.PDF 211.32KB

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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=22V195&docType=RCL

 


 

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