Trailer Brakes May Not Activate – 2022 Coachmen Catalina Travel Trailers

July 8, 2022 NHTSA CAMPAIGN NUMBER: 22V488000

Trailer Brakes May Not Activate

Trailer brakes that fail to activate can increase the risk of a crash.

 

NHTSA Campaign Number: 22V488

Manufacturer Forest River, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 202

 

Summary

Forest River, Inc. (Forest River) is recalling certain 2022 Coachmen Catalina travel trailers. The breakaway switch may be incorrectly wired to the battery disconnect, which can prevent the trailer brakes from activating as intended.

 

Remedy

Dealers will inspect and re-wire the breakaway switch, as necessary, free of charge. Owner notification letters were mailed August 5, 2022. Owners may contact Forest River customer service at 1-574-825-6241. Forest River’s number for this recall is 51-1529.

 

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.safercar.gov.

 

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RECALL 22V488 / 2022-370 REMEDY INSTRUCTIONS

Make(s): CATALINA Model(s): SEE BELOW Model Year(s): 2022	Repair Code: RC-036-22-00-004213 Allotted Time: .30 HRS. Inspection Code: RC-036-05-00-004212 Allotted Time: .10 HRS.
Concern: The breakaway switch wire may be connected to an incorrect circuit. The breakaway switch should be connected to the brake circuit.	Photo(s) Required: NO Prior Authorization Required: NO Part(s) Kit Number: N/A Part(s) Return: N/A

 

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.

 

INSPECT:

STEP 1: HOOK A FULLY CHARGED BATTERY TO THE POSITIVE (RED) AND THE BLACK (NEGATIVE) CABLE;

 

STEP 2: PULL THE BREAKAWAY SWITCH CABLE AND PLUNGER FROM THE BREAKAWAY SWITCH;

– QUICKLY CHECK THE CLEARANCE LAMPS

• CLEARANCE LAMPS DO NOT TURN ON: THE BREAKAWAY SWITCH IS WIRED CORRECTLY AND REQUIRES NO FURTHER ATTENTION. PLUG THE PLUNGER BACK INTO THE BREAKAWAY SWITCH QUICKLY. CLAIM THE INSPECTION CODE ONLY.
• CLEARANCE LAMPS TURN ON: THE BREAKAWAY SWITCH IS WIRED INCORRECTLY AND REQUIRES THE BELOW REMEDY. PLUG THE PLUNGER BACK INTO THE BREAKAWAY SWITCH QUICKLY. DO NOT CLAIM THE INSPECTION CODE.

 

REMEDY:

STEP 1: LOCATE THE BATTERY DISCONNECT SWITCH ON THE FRONT CROSS MEMBER OF THE CHASSIS;

– THIS WILL HELP YOU LOCATE THE JUNCTION BOX INSIDE THE UNDERBELLY OF THE TRAILER.

 

STEP 2: CUT AN ACCESS HOLE ROUGHLY 12” X 12” DIRECTLY BEHIND THE FRONT CROSS MEMBER AND BATTERY DISCONNECT. SET 12” X 12” UNDERBELLY ASIDE FOR LATER USE. THIS WILL GIVE YOU ACCESS TO THE JUNCTION BOX;

 

STEP 3: REMOVE THE COVER PLATE FROM THE JUNCTION BOX AND EXPOSE THE WIRING;
– GENTLY PULL THE WIRING OUT OF THE JUNCTION BOX SO IT CAN BE VIEWED.

 

STEP 4: FIND THE CIRCUIT THAT HAS TWO (2) GREEN WIRES AND A SINGLE (1) BLACK WIRE (FROM THE BREAKAWAY SWITCH) (FIGURE 1);

 

STEP 5: CUT THE BELL CAP OFF THESE THREE WIRES (FIGURE 1);

 

STEP 6: STRIP THE TWO (2) GREEN WIRES BACK AGAIN, TWIST THE WIRE STRANDS TOGETHER, THEN PLACE A NEW BELL CAP ON THEM AND CRIMP THE BELL CAP;

 

STEP 7: FIND THE CIRCUIT THAT HAS ONE (1) PURPLE AND ONE (1) BLUE WIRE (FIGURE 1);

 

STEP 8: STEP 5: CUT THE BELL CAP OFF THESE THREE WIRES (FIGURE 1);

 

STEP 9: STRIP THE PURPLE, BLUE AND BLACK (FROM THE BREAKAWAY) WIRES BACK AGAIN, TWIST THE WIRE STRANDS TOGETHER, THEN PLACE A NEW BELL CAP ON THEM AND CRIMP THE BELL CAP (FIGURE 1);

 

STEP 10: TEST ELECTRIC BRAKE FUNCTIONALITY;

 

STEP 11: USE BLACK TAPE SUCH AS GORILLA TAPE TO SECURE THE 12” X 12” UNDERBELLY PANEL BACK TO THE VEHICLE. ENSURE THE PATCH IS PRESENTABLE TO THE CUSTOMER. THIS WILL ALSO HELP IF IN THE FUTURE THE CUSTOMER OR A DEALER NEEDS TO ACCESS THE CONNECTIONS FOR THE 7 WAY CORD.

 

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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 United States’ National Traffic and Motor Vehicle Safety Act. Forest has decided that a defect, which relates to the motor vehicle safety, exists in certain 2022 Coachmen Catalina 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 breakaway switch wire may be connected to an incorrect circuit. The breakaway switch should be connected to the brake circuit.

 

EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.

During a vehicle separation, the breakaway switch may not activate the trailer brakes. This condition may cause property damage and may lead to a crash.

 

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. However, 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 .30 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:

Catalina & Aurora
Forest River, Inc.
Attn: WARRANTY MANAGER
PO Box 30
Middlebury, IN 46540

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
COACHMEN	CATALINA	2022

 

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9 Associated Documents

Recall Acknowledgement

RCAK-22V488-6552.pdf 689.853KB

 

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Defect Notice 573 Report

RCLRPT-22V488-9459.PDF 216.792KB

 

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Remedy Instructions and TSB

RCRIT-22V488-4646.pdf 414.793KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-22V488-7891.pdf 203.412KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V488-6905.pdf 173.08KB

 

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Recall Quarterly Report #1, 2022-3

RCLQRT-22V488-0647.PDF 211.127KB

 

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Recall Quarterly Report #2, 2022-4

RCLQRT-22V488-7057.PDF 211.229KB

 

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ISSUED Renotification Notice

RCRN-22V488-1610.pdf 175.321KB

 

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Recall Quarterly Report #3, 2023-1

RCLQRT-22V488-2483.PDF 211.307KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V488&docType=RCL

 

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