NHTSA ID Number: 10086681
Manufacturer Communication Number: TSB 446
TSB/Document Date: 2016-12-20
Summary
NEWMAR
CORPORATION HAS DECIDED THAT A DEFECT RELATING TO MOTOR VEHICLE SAFETY EXISTS IN SPECIFIC MOTOR HOMES. NHTSA#: 16V 008 TC#: 2016-018 NEWMAR CORPORATION HAS BEEN ADVISED BY LIPPERT COMPONENTS THAT ON CERTAIN MOTORHOMES USING LCI COACHSTEP ELECTRIC DOUBLE OR TRIPLE ENTRANCE STEPS, THERE IS THE POTENTIAL OF A STRUCTURAL FRACTURE WITHIN THE LIPPERT STEP ASSEMBLY. THERE IS THE POTENTIAL OF A STRUCTURAL FRACTURE OF THE CENTER BOLT OF THE FAN GEAR ASSEMBLY WHICH MAY CAUSE THE FAN GEAR ASSEMBLY TO DISENGAGE FROM THE STEPS. THIS ISSUE CREATES AN UNSTABLE PLATFORM, WHICH COULD CAUSE A PERSON TO FALL AND RESULT IN INJURY.
Connect the motor (2-prong male connector) (Fig. 5A) directly to a 12 volt power supply (Fig. 5C) with
a reversing rocker switch (Fig. 5B).
Fig. 5
Fig. 4
Extend
ONG
Off
12V Power
Supply
Retract
A
Rev: 11.17.2015
A
Page 2
B
C
Coachstep Triple Step Recall Repair Instructions
COACHSTEP TRIPLE STEP RECALL REPAIR INSTRUCTIONS
5.
Uninstall and remove the linkage assembly (Fig. 6A)
using a 9/16" wrench or socket and a 1/2" wrench.
A
Fig. 6
Ensure that the jack stand(s)
is securely placed under the
bottom step prior to removing
the linkage. The steps will
be able to rotate freely after
linkage removal which could
cause serious personal injury or
damage to the coach.
Note: If the linkage cannot be fully removed from the
assembly, adjust the jack stand(s) to allow a
minimal amount of retraction and then extend
and retract the motor controls as necessary to
help free the linkage.
6.
7.
8.
Once the linkage is removed, run the motor to full
extension.
Adjust the jack stand(s) if necessary to ensure that
the steps remain fully extended until the new linkage
is installed.
Install the new linkage (Fig. 7B) to the fan gear first
with a 1 1/2" bolt (Fig. 7C) and toplock nut (Fig. 7A).
Fan gear shown
transparent
to show detail.
Fig. 7
B
A
C
Fig. 8
9.
Adjust the linkage length as necessary until the 1 3/4"
bolt can be inserted through both the linkage end
and the shaft leaf. (Fig. 8).
Rev: 11.17.2015
Page 3
Coachstep Triple Step Recall Repair Instructions
COACHSTEP TRIPLE STEP RECALL REPAIR INSTRUCTIONS
10. Install the other half of the linkage (Fig. 9A) to the shaft
leaf (Fig. 9B) with the 1 3/4" bolt (Fig. 9D) and toplock nut
(Fig. 9C).
Fan gear shown
transparent
to show detail.
Fig. 9
Note: Manually extend or retract the fan gear as needed to
align the linkage end with the shaft leaf through-hole.
Steps should remain at full extension while supported
by the jack stand(s).
11. Tighten the nuts on both linkage ends to 26 ft-lbs of
torque.
12. After moving safely away from underneath the motorized
steps, remove the jack stand(s) and test the assembly
for proper extension and retraction, using the reversing
rocker switch. Replace the jack stand(s) under the bottom
step once the testing is complete.
13. Disconnect the 2-prong motor connector from the
manual 12 volt power supply and reconnect to the motor
control box.
14. Reconnect the 4-prong connector from the motor control
box to the coach power supply. Ensure that jacks stand(s)
is placed appropriately to stop any potential attempt for
automatic retraction.
15. After moving safely away from underneath the motorized
steps, remove the jack stand(s) and test the steps for full
operation via the standard operation of the coach.
A
B
C
D
Retainer Bracket Installation
1.
2.
3.
Fully extend the steps (until the motor stops).
Place a jack stand under the bottom step to prevent any potential attempt for automatic retraction.
Disconnect the power supply (4-prong connector- Fig. 10A) after extending.
Note: Jack stand may be removed once power supply is disconnected.
Fig. 10
A
Rev: 11.17.2015
Page 4
Coachstep Triple Step Recall Repair Instructions
COACHSTEP TRIPLE STEP RECALL REPAIR INSTRUCTIONS
4.
Remove the two motor housing bolts and lock washers (Fig. 11A). The lock washers are shown on the
motor housing bolts in the images.
Fig. 11 - Detail
Fig. 11
A
A
A
A
Assembling the Retainer Bracket
1.
2.
3.
Install the 5/16 - 18 x 3/4" bolt (Fig. 12A) into the appropriate hole in the retainer bracket (Fig. 12C).
Tighten the lock nut (Fig. 12E) onto the bolt (Fig. 12A) until the lock nut contacts the retainer bracket.
Install the rubber bumper (Fig. 12B) into the hole in the retainer bracket (Fig. 12D).
Fig. 12
A
Retainer Bracket
B
C
Triple Step
Mounting Holes
D
A
E
Rev: 11.17.2015
Page 5
Coachstep Triple Step Recall Repair Instructions
COACHSTEP TRIPLE STEP RECALL REPAIR INSTRUCTIONS
Installing the Retainer Bracket Assembly
1.
2.
3.
4.
Clean any dirt or debris from the hex socket on the fan gear shoulder bolt (if necessary) (Fig. 13G).
Ensure that all the motor mount spacers (6 total - Fig. 13H) are still in place.
Insert the 5/16 - 18 x 3/4" bolt (Fig. 13D) into the hex socket of the fan gear shoulder bolt (Fig. 13G).
Install the 6mm - 10 x 63.5 mm bolts and 6 mm lock washers (Fig. 13E) through the appropriate
mounting holes in the retainer bracket and into the motor housing.
Note: If alignment issues for the mounting bolts arise, loosen the lock nut on the 5/16 - 18 x 3/4" bolt (Fig. 13D)
to allow the bolt to slide within its oversized hole. Once the mounting bolts are properly aligned,
re-tighten the lock nut.
5.
Install 3 tek screws (Fig. 13B) through the retainer bracket (Fig. 13C) and control box flange (Fig. 13A),
and into the step housing (Fig. 13F) to secure that end of the retainer bracket.
Note: Pre-drilling 1/8" pilot holes prior to installing the tek screws may help simplify the installation.
6.
Tighten the screw until the retainer bracket is flush with the control box flange and the foam washers
on the tek screws begin to compress.
Note: Be sure to apply proper pressure and drill rotation speed on the drill to avoid stripping the selfdrilling threads on the tek screws.
Fig. 13
C
D
E
B
A
G
F
7.
8.
9.
H
Place a jack stand under the bottom step to prevent any potential attempt for automatic retraction.
Reconnect the 4-prong connector from the motor control box (Fig. 10A) to the coach power supply. Ensure
that jacks stand(s) is placed appropriately to stop any potential attempt for automatic retraction.
After moving safely away from underneath the motorized steps, remove the jack stand(s) and test the
steps for full operation via the standard operation of the coach.
Rev: 11.17.2015
Page 6
Coachstep Triple Step Recall Repair Instructions
Prod #
110157
110158
110159
110163
110164
110165
110166
110167
110168
110169
110170
110171
110172
110173
110174
110175
110176
110177
110178
110179
110180
110181
110182
110183
110187
110188
110190
110191
110192
110193
110194
110195
110196
110197
110198
110200
110201
110202
110203
110204
110205
110207
110208
110209
110210
110211
110212
110213
110217
110219
110220
VIN Number
1F6MF53Y570
1F6NF53Y660
1F6NF53Y060
1F6NF53Y960
1F6NF53Y260
1F6NF53Y460
1F6MF53Y270
1F6NF53Y860
1F6MF53Y270
1F6MF53Y970
1F6NF53YX60
1F6MF53Y770
1F6NF53Y160
1F6MF53Y470
1F6NF53Y360
1F6MF53Y470
1F6MF53Y270
1F6NF53YX60
1F6NF53Y260
1F6NF53Y060
1F6MF53Y470
1F6NF53Y160
1F6MF53Y670
1F6MF53Y670
1F6MF53Y870
1F6NF53Y460
1F6MF53Y370
1F6MF53YX70
1F6NF53Y660
1F6MF53Y870
1F6NF53Y260
1F6NF53Y860
1F6NF53Y060
1F6NF53YX60
1F6NF53Y560
1F6MF53Y070
1F6MF53YX70
1F6NF53Y160
1F6MF53Y170
1F6NF53Y160
1F6NF53Y160
1F6NF53Y360
1F6MF53Y570
1F6NF53Y560
1F6NF53Y360
1F6MF53Y870
1F6MF53YX70
1F6NF53Y760
1F6NF53Y370
1F6NF53Y570
1F6NF53Y770
Year
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
Brand
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
BS
Type Floor Chass Date In Prod Date Off Prod
2901 F
CA
6/11/2007
6/21/2007
3202 F
CA
6/7/2007
6/19/2007
3304 F
CA
5/30/2007
6/7/2007
3202 F
CA
5/30/2007
6/7/2007
3102 F
CA
5/30/2007
6/11/2007
3202 F
CA
6/1/2007
6/13/2007
2901 F
CA
6/4/2007
6/13/2007
3202 F
CA
6/14/2007
6/26/2007
2901
CA
F
7/23/2007
8/1/2007
2901 F
CA
6/21/2007
7/16/2007
2901 F
CA
6/21/2007
7/16/2007
2701 F
CA
7/11/2007
7/23/2007
3201 F
CA
6/27/2007
7/19/2007
2901 F
CA
8/1/2007
8/14/2007
3304 F
CA
7/19/2007
7/31/2007
2901 F
CA
7/23/2007
7/31/2007
2901 F
CA
7/30/2007
8/8/2007
3201 F
CA
8/2/2007
8/14/2007
3304 F
CA
8/14/2007
8/23/2007
3201 F
CA
8/13/2007
8/22/2007
2901 F
CA
8/8/2007
8/20/2007
3202 F
CA
8/9/2007
8/21/2007
2901 F
CA
8/21/2007
8/30/2007
2901 F
CA
8/27/2007
9/5/2007
2901 F
CA
9/6/2007
9/18/2007
3304 F
CA
8/27/2007
9/6/2007
2701 F
CA
9/12/2007
9/24/2007
2901 F
CA
9/19/2007
10/1/2007
3304 F
CA
9/5/2007
9/13/2007
2901 F
CA
8/28/2007
9/6/2007
3304 F
CA
8/22/2007
8/30/2007
3201 F
CA
9/5/2007
9/13/2007
3202 F
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TSB/Document ID: TSB 446
Replacement Service Bulletin Number:
MFR Communication Date: 2016-02-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
MFR Component Subsystem:
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