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October 13, 2022 NHTSA CAMPAIGN NUMBER: 22V770000
Auxiliary Power System Wires Incorrectly Routed
Damaged or frayed wires can cause an electrical short, increasing the risk of a fire.
NHTSA Campaign Number: 22V770
Manufacturer Storyteller Overland
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 58
Summary
Storyteller Overland (Storyteller) is recalling certain 2022-2023 Storyteller Mode LT motorhomes. The wires connecting the secondary alternator to the auxiliary power system may be improperly routed, allowing them to contact the CV axle shaft and damage the wires.
Remedy
Dealers will reroute the wiring and add a heat shield. In addition, wires will be inspected for damage and replaced as necessary. Repairs will be performed free of charge. Owner notification letters were mailed October 21, 2022. Owners may contact Storyteller customer service at 1-888-999-7442.
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.
October 2022
* * * IMPORTANT SAFETY RECALL * * *
This notice applies to your vehicle,
a Storyteller Overland MODE LT, with the VIN shown below.
NHTSA Recall: 22V770
Your Vehicle Identification Number (VIN):
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Storyteller Overland, LLC has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 Storyteller Overland MODE LT’s.
We apologize for any inconvenience and want to assure you that, with your assistance, we will correct this. Our commitment, along with your dealers, is to provide you with the highest level of customer service.
OWNERS CAN CONTINUE TO USE THEIR VEHICLES. HOWEVER, IF YOU ARE DRIVING THE MODE LT, THE VOLTA SYSTEM MUST BE TURNED OFF UNTIL THE RECALL REPAIR IS COMPLETE. YOU CAN USE THE VOLTA SYSTEM WITH THE ENGINE OFF.
What is the issue? The Storyteller Overland MODE LT contains wiring that connects the secondary alternator system to its auxiliary power system. This wiring includes: two 2/0 AWG wires and three wires for alternator control. Due to the potential improper routing of these wires, there is a risk of contact with the driver’s side CV axle shaft.
What is the risk? Contact between the wires and CV axle shaft could cause physical damage to the insulation of the wires, potentially creating unprotected/frayed conductors. An unprotected/frayed conductor could cause an electrical short, creating the risk of a fire, personal injury, or property damage.
What will Storyteller Overland and your dealer do? Storyteller Overland authorized dealers will inspect, then re-route the wiring and add additional cable management components. The dealer will also replace any wiring, if necessary. There will be no charge to you for this update.
How long will it take? The time needed to complete this recall will be approximately 2 hours. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.
What should you do? Please contact your local Storyteller Overland authorized dealer without delay and request a service date for NHTSA Recall: 22V770. To find the nearest dealer, go to www.storytelleroverland.com/pages/find-a-dealer or call 888-999-7442. Provide the dealer with your VIN, which is printed near the top of this letter. Also, please email warranty@storytelleroverland.com when your appointment is scheduled and Storyteller Overland will make sure your dealer has everything needed to complete the update in advance.
What if you no longer own this vehicle? You received this notice because government regulations require that we send notifications to the last known owner of record. If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. If you do not have that information please return to Storyteller Overland in the self addressed envelope provided.
Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Can we assist further? If you are having difficulties getting your vehicle repaired promptly and without charge, please contact us directly for assistance at 888-999-7442.
If an authorized Storyteller Overland dealer for any reason is unable to remedy the situation without charge, or within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, S.E., Washington, D.C. 20590 or call the toll-free Auto Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153); or go to https://www.safercar.gov.
Thank you for your attention to this important matter.
Storyteller Overland Customer Service Department
Chronology :
On September 29th, 2022, the auxiliary power system on a prototype MODE LT was identified as not charging from the secondary alternator. Upon investigation, STO technicians noticed wiring from the secondary alternator system to the auxiliary power system showed abrasion from contact with the driverโs side CV axle shaft. STOโs quality team then investigated vehicles on the production line and noticed inconsistent wire routing. On October 10, 2022, an internal meeting was held to discuss these findings with STOโs internal safety committee, and the committee decided to issue a voluntary recall.
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
STORYTELLER OVERLAND | MODE LT | 2022-2023 |
8 Associated Documents
Recall Acknowledgement
RCAK-22V770-7149.pdf 646.283KB
Defect Notice 573 Report
RCLRPT-22V770-2084.PDF 214.508KB
Recall 573 Report – 10/18/2022
RCLRPT-22V770-2914.PDF 214.592KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V770-3391.pdf 324.49KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V770-8298.pdf 8256.507KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V770-1769.PDF 211.133KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V770-3253.PDF 211.223KB
Recall Quarterly Report #3, 2023-2
RCLQRT-22V770-7436.PDF 211.311KB
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1 Storyteller Overland, LLC Customer Service Department 428 Industrial Lane Birmingham, AL 35211 October 2022 * * * IMPORTANT SAFETY RECALL * * * This notice applies to your vehicle, a Storyteller Overland MODE LT, with the VIN shown below. NHTSA Recall: 22V770 Your Vehicle Identification Number (VIN): This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Storyteller Overland, LLC has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 Storyteller Overland MODE LT’s. We apologize for any inconvenience and want to assure you that, with your assistance, we will correct this. Our commitment, along with your dealers, is to provide you with the highest level of customer service. OWNERS CAN CONTINUE TO USE THEIR VEHICLES. HOWEVER, IF YOU ARE DRIVING THE MODE LT, THE VOLTA SYSTEM MUST BE TURNED OFF UNTIL THE RECALL REPAIR IS COMPLETE. YOU CAN USE THE VOLTA SYSTEM WITH THE ENGINE OFF. What is the issue? The Storyteller Overland MODE LT contains wiring that connects the secondary alternator system to its auxiliary power system. This wiring includes: two 2/0 AWG wires and three wires for alternator control. Due to the potential improper routing of these wires, there is a risk of contact with the driver’s side CV axle shaft. 2 What is the risk? Contact between the wires and CV axle shaft could cause physical damage to the insulation of the wires, potentially creating unprotected/frayed conductors. An unprotected/frayed conductor could cause an electrical short, creating the risk of a fire, personal injury, or property damage. What will Storyteller Overland and your dealer do? Storyteller Overland authorized dealers will inspect, then re-route the wiring and add additional cable management components. The dealer will also replace any wiring, if necessary. There will be no charge to you for this update. How long will it take? The time needed to complete this recall will be approximately 2 hours. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time. What should you do? Please contact your local Storyteller Overland authorized dealer without delay and request a service date for NHTSA Recall: 22V770. To find the nearest dealer, go to www.storytelleroverland.com/pages/find-a-dealer or call 888-999-7442. Provide the dealer with your VIN, which is printed near the top of this letter. Also, please email warranty@storytelleroverland.com when your appointment is scheduled and Storyteller Overland will make sure your dealer has everything needed to complete the update in advance. What if you no longer own this vehicle? You received this notice because government regulations require that we send notifications to the last known owner of record. If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner. If you do not have that information please return to Storyteller Overland in the self addressed envelope provided. Please note: Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Can we assist further? If you are having difficulties getting your vehicle repaired promptly and without charge, please contact us directly for assistance at 888-999-7442. If an authorized Storyteller Overland dealer for any reason is unable to remedy the situation without charge, or within a reasonable amount of time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, S.E., Washington, D.C. 20590 or call the toll-free Auto Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153); or go to https://www.safercar.gov. Thank you for your attention to this important matter. Storyteller Overland Customer Service Department
**************************************************************************************************************
Storyteller Overland, LLC Customer Service Department 428 Industrial Lane Birmingham, AL 35211 November 1, 2022 TO: Storyteller Overland, LLC Dealers SUBJECT: NHTSA Recall: 22V-770 Storyteller Overland, LLC (“STO”) has decided that a defect which relates to motor vehicle safety exists in certain 2022-2023 Storyteller Overland MODE L T’s, and STO has issued a voluntary recall in accordance with the National Traffic and Motor Vehicle Safety Act, as amended. These MODE LTs were manufactured between 4-12-22 and 10-10-22. STO has notified MODE LT owners of this recall, and MODE LT owners are already reaching out to STO Dealers to schedule repairs. DO NOT DELIVER TO A CUSTOMER ANY MODE LTs SUBJECT TO THIS RECALL UNTIL CORRECTIVE ACTION HAS BEEN TAKEN. What is the reason for this recall? The Storyteller Overland MODE LT contains wiring that connects the secondary alternator system to its auxiliary power system. This wiring includes: two 2/0 AWG wires and three wires for alternator control. Due to the potential improper routing of these wires, there is a risk of contact with the driver’s side CV axle shaft. What is the risk? Contact between the wires and CV axle shaft could cause physical damage to the insulation of the wires, potentially creating unprotected/frayed conductors. An unprotected/frayed conductor could cause an electrical short, creating the risk of fire, personal injury, or property damage. STO is not aware of any injuries or property damage associated with this issue. What is the fix? Please see the instructions attached to this letter for repair instructions and required parts. Please coordinate with STO’s Customer Service Department to ensure required parts have been shipped to you in time for each MODE LT owner’s appointment. When the service has been completed, please submit a completed recall checklist in the form attached to this email to STO’s Customer Service Department at warranty@storytelleroverland.com. 1 Dealers are to service all vehicles subject to this campaign at no charge to owners regardless of mileage, age of vehicle, or ownership from this time forward. STO will reimburse your service department for the labor time set forth in the repair instructions. Thank you for your prompt attention to this important matter. -Storyteller Overland Team Enclosures 2 -~c..~ + STDRYTELLER DVERLANUยฎ NHTSARecall # 22V-770 Inspection & Repair Instructions Rev10282022 Overview: This document provides instructions for inspecting and repairing the wiring for the secondary alternator in accordance with NHTSA recall number 22V-770. Please contact Storyteller should you have any questions or need any assistance with these instructions. Applicable Vehicles: 2022-2023 Storyteller Mode LT vans produced between 4/12/2022 and 10/10/2022 Safety Alert: This procedure requires work underneath the van and around potentially extremely hot exhaust components. Only perform this procedure with the ignition off and when the van has had adequate time to cool down the exhaust components. The use of an approved lift for the van is highly recommended for gaining access to underneath the van. Tools and Supplies Needed: โข Flashlight โข Flush Cutters โข 8mm Socket โข Ratchet Handle โข 7mm Socket Items provided by Storyteller Overland โข Heat Shield Sleeving, 126″ Length Total โข Dual Swivel Saddle Spacer – Oty 3 โข Heavy Duty 12″ Cable Ties – Oty 30 โข Spring Clamp Pliers โข Trim Removal Tool โข 13mm Socket โข 10mm Socket โข 3″ Socket Extension โข 18 ft-lb Torque Wrench โข 10.5 ft-lb Torque Wrench โข Paint pen for torque striping โข As needed – Automotive black paint Flat Rate Time: 2 Hours for Inspection and Repair without Damaged Wiring 2.5 Hours for Inspection and Repair with Damaged Wiring Inspection Procedure: 1. Ensure the van ignition and the Volta system are turned off. To ensure the Volta system is off, check that the “System On/Off” button is not illuminated and the control screens are off on the wall just above the passenger’s side sliding door. Press the “System On/Off” button once to turn off if needed. See figure 1. Figure 1 Ensure the Volta system is turned off 2. Access underneath the rear of the van from the passenger side just in front of the rear wheel. NOTE: It is highly encouraged to use a lift for easy access underneath the van. 3. Locate the 2/0 awg cables wrapped in heat sleeving that are routed across the van floor from the passenger’s side to the driver’s side above the exhaust pipes, brake lines, driveshaft, etc. Verify the cables are not supported above the brake lines and exhaust pipes in the two locations as shown in figure 1 below. If they are not supported {such as the cables in figure 2), repair per the procedures in steps 14-16, then proceed to step 4 to continue inspection. If they are supported, continue to step 4. Figure 2 Cables hanging unsupported on the brake lines and above exhaust pipes 4. The next inspection steps require disassembly of the secondary alternator wiring from the alternator back to the front of the fuel tank. 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 1 5. Use an 8mm socket and ratchet handle to remove the (4) bolts holding the intercooler and charge air pipes to the subframe as shown in figure 3. Set bolts aside for reassembly later. Figure 3 Remove (4) Bolts 6. Use a 7mm socket and ratchet handle to loosen the hose clamps on the large tube just before the intercooler: (2) clamps on the driver’s side and (1) clamp on the passenger’s side. See figures 4a and 4b. Figure 4b Fi ure 4a Passenger’s Side – Loosen (1) hose clamp Driver’s Side – Loosen (2) hose clamps 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 2 7. Use spring clamp pliers to loosen the spring clamp on the recirc hose and disconnect the hose from the front side of the charge air pipe tube. See figure 5. 8. Disconnect harness connector on the driver’s side of the recirc hose and use a trim removal tool to pull out the cable tie mount securing the harness. See figure 6. Then, remove the intercooler pipe and set aside Remove cable Figure 6 Disconnect connector and remove cable tie mount Figure 5 Loosen spring clamp and disconnect hose 9. Use a 7mm socket and ratchet handle to loosen the hose clamps on the charge air pipe: (1) clamp on driver’s side and (1) clamp on passenger’s side. See figures 7a and 76. Then, remove the charge air pipe and set aside Figure 7a Loosen hose clamp on driver’s side 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 7b Loosen hose clamp on passenger’s side 3 10. Cut any cable ties that secure the secondary alternator wiring (consisting of positive 2/0 awg cable, ground 2/0 awg cable, 58V ALT harness branch, ALT harness branch, and autostart harness branch) in place along the way from the front of the fuel tank to the end of the wiring. 11. Disconnect the “ALT” harness branch connector from the port at the top of the secondary alternator. Use a 13mm socket and small ratchet handle to remove the positive 2/0 awg cable and “58V ALT” harness branch from the alternator post. Set nut aside. The post is easily accessed from underneath the van and reaching up in between the intercooler/charge air pipes and the oil filter. See figures 8a and 8b lntercooler/charge air Figure Sa: View from bottom Locate secondary alternator and disconnect wiring Figure Sb: View from top Locate secondary alternator and disconnect wiring 12. Disconnect the ground 2/0 awg cable from the factory alternator’s mounting bracket located toward the passenger’s side using a 10mm socket and ratchet handle. Once cable is removed, reinstall bolt and torque to 18 ft-lbs. Note: If the cable is not found on the factory alternator, it may instead be fastened to the driver’s side chassis subframe. If that is the case, remove the cable from the subframe and touch up the scuffed-up area with automotive black paint as needed. See figure 9 Factory alternator OR Figure 9 Disconnect ground cable 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Grounded to subframe 4 13. With all of the secondary alternator wires loose, pull the wiring out from under the chassis all the way back to the front of the fuel tank so the wiring can be inspected as shown in figure 10. Remove any existing heat sleeving from this section of the wiring. Fully inspect the condition of all wire loom, cable lugs, ring terminals, and harness connectors looking for signs of thermal and/or mechanical damage of any kind. NOTE: If any damage is found, document and provide Storyteller Overland with pictures of all damage and contact Storyteller Overland for further instruction to repair the damaged wires/components. If no thermal or mechanical damage is found, proceed to step 17 for the remaining repair procedure. Figure 10 Remove wiring from chassis all the way back to front of fuel tank. Inspect for damage Repair Procedure: 14. Using one of the supplied heavy-duty cable ties, secure the heat sleeved cables above the brake lines by routing the cable tie through the small hole and out the large hole in the frame crossmember just above the brake lines. Fasten the cable tie around the cables, pull tight, and clip the excess cable tie end off with flush cutters. See figure 11 . Figure 11 Secure cables above brake lines with a heavy-duty cable tie. Use these holes in the crossmember Should look like this after step 14 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 5 15. Route another heavy-duty cable tie through the opening where the frame crossmember meets the frame rail on the passenger’s side of the brake lines from the previous step. Fasten the cable tie around the cables, pull tight, and clip the excess cable tie end off with flush cutters. See figure 12. Figure 12 Fasten cable tie through the opening where the frame crossmember meets the frame rail, then around the cables Frame Rail Install and fasten cable tie Frame Crossmember 16. The cables should now be secured above the brake lines and exhaust components as shown in figure 13. 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 13 Harness now secured above brake lines and exhaust components 6 17. Hold the ends of the “58V ALT” harness and the positive 2/0 awg together so the ring terminal/lug can be overlapped. Then hold the “ALT” harness branch connector about 1 ” back from the cable lug. Secure wiring with a cable tie. See figure 14. “58V ALT” ring terminal Figure 14 Secure wiring ends together as arranged in the picture. Secure with cable tie Positive 2/0 awg lug “ALT” connector 18. Use about (7) more cable ties to bundle the positive 2/0 awg cable with the other harness branches back to where the autostart harness branches out. NOTE: Leave the ground 2/0 awg cable separate. See figure 15. Figure 15 Bundle all wiring except ground cable together 19. Cut a 66″ long section of heat sleeving and slide onto the wiring (including the ground cable) until about 2 feet of wiring extends out the end of the heat sleeving. See figure 16. 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 16 Slide heat sleeving over end of wiring so 2 ft of wiring sticks out 7 20. Cut and install an 18″ section of heat sleeving over the ground cable and the positive cable bundle so the sleeving stops just before the cable lugs. Secure the sleeving to the cables with cable ties. Then slide the end of the 66″ section of heat sleeving just past the end of the two 18″ sections and secure both ends of the 66″ section with a cable tie. See figure 17. Figure 17 Slide 18″ sections of heat sleeving over ends of wiring and secure with cable ties. Then overlap the end of the 66″ heat sleeve section on top and secure with cable tie 21. Begin routing the wiring bundle from the front of the fuel tank forward along the bottom of the frame rail. The wiring should pass over the evap lines and between the evap canister and the evap pump. See figure 18 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 18 Route wiring along bottom of frame rail between the evap pump and evap canister Wiring bundle Evap canister 8 22. Continue routing the wiring forward between the frame rail and exhaust heat shielding toward the front CV axle shaft. Make sure the bundle goes above the factory harness connector mounted just above the tie rod. See figure 19 Route over een frame rail heat shielding Figure 19 Route wiring between frame rail and heat shielding, then above harness connector that is above the tie rod 23. When at the front CV axle shaft, run the wire bundle under the steering shaft then over the two factory coolant lines. Route the wiring between the frame rail and driver’s side engine mount on top of the frame crossmember. See figure 20 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Route over frame crossmember Figure 20 Ensure wiring runs along the frame rail, between the steering shaft and CV axle shaft then over the frame crossmember between the engine mount and frame rail. CV Axle Shaft 9 24. The loose ends of the wiring bundle should now be coming down near the driver’s side intercooler and charge air piping. Route the positive cable bundle up between the pipes and toward the secondary alternator as shown in figure 21a. Slide the positive cable lug onto the alternator post first, then the “58V ALT” ring terminal second. Hand start the nut onto the post then torque to 10.5 ft-lbs with a 13mm socket and torque wrench. Use a paint pen to torque stripe the nut. Reconnect the “ALT” harness connector to the top of the alternator. See figure 21b. Route positive cable up between pipes Figure 21a Route positive cable bundle up between the charge air and intercooler pipes toward the alternator post Figure 21b Torque positive cable and “58V ALT” wire to alternator. Connect “ALT” harness connector 25. Next, route the ground cable over toward the engine. Using a 10mm socket, 3″ socket extension and a ratchet handle, remove the rearmost oil pan bolt of the two bolts at the front driver’s side corner of the engine next to the oil filter. Fasten the ground cable lug to this location and torque the bolt to 18 ft-lbs. Use a paint pen to torque stripe the bolt. See figure 22 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 22 Fasten ground cable to oil pan bolt next to oil filter. Torque bolt to 18 ft-lbs and torque stripe 10 26. Using a dual swivel saddle spacer and (2) cable ties, secure the wiring to the intercooler pipe. See figure 23 Figure 23 Secure wiring to intercooler pipe with dual swivel saddle spacer and cable ties 27. Using a dual swivel saddle spacer and (2) cable ties, secure the wiring to the factory harness along the frame rail just in front of the driver’s side motor mount where the cables turn upward toward the alternator. See figure 24. 28. Use the third dual swivel saddle spacer and (2) cable ties to secure the wiring to the two coolant lines above the driver’s side CV axle shaft. Ensure the wiring is pulled away from both the steering shaft and the CV axle shaft. See figure 25 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 24 Secure wiring to factory harness along frame rail with dual swivel saddle spacer and cable ties Figure 25 Secure wiring to the two coolant pipes above the CV axle shaft with dual swivel saddle spacer and cable ties CV Axle Shaft 11 29. Use a cable tie to secure the wiring to the factory harness above the tie rod as shown in figure 26. 30. Use a cable tie to secure the wiring between the frame rail and exhaust heat shield. As shown in figure 27, route the cable tie through the hole in the bottom of the frame rail then out the inboard side of the frame rail and around the wiring. Figure 26 Secure wiring to the factory harness above the tie rod with a cable tie Figure 27 Secure wiring to the frame rail with a cable tie 31. Use a cable tie to secure the wiring to the factory harness that is mounted to the frame rail just in front of the fuel tank. See figure 28 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 28 Secure wiring with a cable tie to the factory harness that is mounted to the frame rail just in front of the fuel tank Fuel Tank 12 32. The wiring routing is now complete. Ensure the wiring is not touching and is not capable of touching any moving chassis components including but not limited to the front CV axle shaft, steering shaft, tie rod. Ensure all cable tie ends are clipped with flush cutters. 33. Reassemble the chassis components by following steps 5 – 9 in reverse order. 34. Once reassembled, test the functionality of the system by pressing the “System On/Off” button and waiting for the system to fully turn on, then turn on van ignition, then rev the engine to 1500 RPM. If the system is working properly, the Volta screen will display the icon shown in figure 29 and the power flow meter will show a positive power flow reading indicating the system is charging from the alternator. If the icon does not appear or the power flow reading is negative, begin troubleshooting. 5 T DR Y T EL L E R DV ER L A N D .. Rev10282021 Figure 29 If system is working correctly, the green alternator icon shown in the picture will appear on the Volta screen and the power flow reading will be positive 13 -~c..~ + STDRYTELLER DVERLANUยฎ Recall# 22V-770 Checklist Rev10282022 Instructions: Complete this checklist during the procedure outlined in the document” 10282022 Recall# 22V-770 Inspection and Repair Instructions.” Once the recall repair is complete, supply completed form to Storyteller Overland via email at warranty@storytelleroverland.com Service Center Name: __________ _ Date: ______ _ Name/Employee# of person(s) performing recall service: ________________ _ Van Owner’s Name: ____________ _ Van’s VIN: __________ _ Step 3: Were 2/0 awg cables supported above the brake lines? Yes _ No __ Step 12: If applicable, retorque factory alternator mounting bracket bolt to 18 ft-lbs and initial: __ _ Step 13: Was any damage to the wires found? Yes__ No__ If yes, list what damage was found on the lines below along with taking pictures of all damage to send to Storyteller Overland: Steps 14-16: If cables were not initially supported, fix per the procedure and initial here: ____ _ Steps 17-20: Cables covered with (1) 66″ section and (2) 18″ sections of heat sleeving per the procedure and secured with cable ties. Initial here: ___ _ Step 24: Positive cable and “58V ALT” wire fastened to alternator and torqued to 1 O.Sft-lbs (initial): __ “ALT” harness connector installed to port on top of alternator (initial): __ 1 Step 25: Ground cable fastened to oil pan bolt and torqued to 18 ft-lbs (initial): __ _ Step 26: Wiring secured to intercooler pipe with saddle spacer and cable ties (initial): ___ _ Step 27: Wiring secured to factory harness with saddle spacer and cable ties (initial): ___ _ Step 28: Wiring secured to coolant lines with saddle spacer and cable ties (initial): ___ _ Step 29: Wiring secured to factory harness with cable tie (initial): ___ _ Step 30: Wiring secured to frame rail with cable tie (initial): ___ _ Step 31: Wiring secured to factory harness with cable tie (initial): ___ _ Step 32: Wiring is routed per the repair procedure and not currently touching or capable or touching any moving chassis component (initial): ___ _ Step 33: Reinstall charge air pipe and tighten clamps – 1 on each side (initial): __ _ Reconnect harness connector to recirc valve and reattach cable tie mount (initial): __ _ Reconnect recirc hose and secure with spring clamp (initial): __ _ Tighten intercooler piping hose clamps- 2 on driver side, 1 on passenger side (initial): _ _ Reinstall and tighten (4) bolts to secure intercooler and intake piping to subframe (initial): __ Step 34: System passed test as outlined in procedure (initial): _ _ 5 T DR Y T EL L E R DV ER L A N D .. 2 Rev10282022
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-770 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Storyteller Overland Submission Date : OCT 18, 2022 NHTSA Recall No. : 22V-770 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Storyteller Overland Address : 428 Industrial Lane BIRMINGHAM AL 35211 Company phone : 9997442 Population : Number of potentially involved : 58 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2023 Ford Transit Storyteller Mode LT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : The recall population was determined by identifying all MODE LT vans from the start of production through the date Storyteller Overland, LLC (โSTOโ) stopped production to remedy the issue. The recalled products include all Storyteller Mode LT’s that have been produced. There are 58 total Storyteller Mode LT’s that will be affected by this recall. Production Dates : APR 12, 2022 – OCT 10, 2022 VIN Range 1 : Begin : 1FTBW2X80LKB49371 End : 1FTBW2XG3NKA36010 Not sequential Description of Defect : Description of the Defect : The Storyteller Overland MODE LT contains wiring that connects the secondary alternator to its auxiliary power system. This wiring includes: two 2/0 AWG wires and three wires for alternator control. Due to the potential improper routing of these wires, there is a risk of contact with the driver’s side CV axle shaft. STO is not aware of any injuries or property damage associated with this issue. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Contact between the wires and the CV axle shaft could cause physical damage to the insulation of the wires, potentially creating unprotected/frayed conductors. An unprotected/frayed conductor could cause an electrical short, Part 573 Safety Recall Report 22V-770 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 creating the risk of thermal damage, personal injury, or property damage. STO is not aware of any injuries or property damage associated with this issue. Description of the Cause : The wiring of the Mode LT connecting the secondary alternator system to the auxiliary power system has been inconsistently routed without sufficient measures taken to prevent the wires from coming into contact with the driver’s side CV axle shaft. Identification of Any Warning that can Occur : The secondary alternator system may not charge the auxiliary power system, or it may not charge consistently, while the vehicle is running. A customer may notice a burning smell and/or observe wiring damage near the driver’s side CV axle shaft. Involved Components : Component Name 1 : Volta External Harness Flex Fode Component Description : Volta External Harness Flex Fode Component Part Number : F3X-1142H0-00424 Component Name 2 : Custom Automated Services Universal Jumper Wire Ki Component Description : Universal Jumper Wire Kit Component Part Number : U3X-114211-00679 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : On September 29th, 2022, the auxiliary power system on a prototype MODE LT was identified as not charging from the secondary alternator. Upon investigation, STO technicians noticed wiring from the secondary alternator system to the auxiliary power system showed abrasion from contact with the driverโs side CV axle shaft. STOโs quality team then investigated vehicles on the production line and noticed inconsistent wire Part 573 Safety Recall Report 22V-770 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 routing. On October 10, 2022, an internal meeting was held to discuss these findings with STOโs internal safety committee, and the committee decided to issue a voluntary recall. Description of Remedy : Description of Remedy Program : The remedy to correct this defect will involve inspection of wiring for correct routing and to determine if any damage is present. If there is any damage, replacement wiring will be installed. Regardless of whether any damage is present, the wiring will be rerouted with heat-resistant ties away from the driverโs side CV axle shaft, and a heat shield will be added around the wiring as a redundancy. The remedy will be performed at no cost to the consumer at an STO authorized location. All the Vehicles that are affected by this recall are new vans that will be covered under Storyteller’s limited warranty policy. How Remedy Component Differs from Recalled Component : The remedy is primarily assembly process related; provided, however, the remedy components will involve additional wire protection as well as new routing/securing of the wires. Identify How/When Recall Condition was Corrected in Production : The recall condition was corrected in production with updated process instructions regarding wiring routing with proper fastening components and additional wire protection. This process will be verified on the production line. Recall Schedule : Description of Recall Schedule : Dealer and owner notification letters will be sent within the 60-day requirement. Planned Dealer Notification Date : OCT 13, 2022 – DEC 13, 2022 Planned Owner Notification Date : OCT 13, 2022 – DEC 13, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-770 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Storyteller Overland Submission Date : OCT 13, 2022 NHTSA Recall No. : 22V-770 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Storyteller Overland Address : 428 Industrial Lane BIRMINGHAM AL 35211 Company phone : 9997442 Population : Number of potentially involved : 58 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2022-2023 Ford Transit Storyteller Mode LT Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS Descriptive Information : The recall population was determined by identifying all MODE LT vans from the start of production through the date Storyteller Overland, LLC (โSTOโ) stopped production to remedy the issue. The recalled products include all Storyteller Mode LT’s that have been produced. There are 58 total Storyteller Mode LT’s that will be affected by this recall. Production Dates : APR 12, 2022 – OCT 10, 2022 VIN Range 1 : Begin : 1FTBW2X80LKB49371 End : 1FTBW2XG3NKA36010 Not sequential Description of Defect : Description of the Defect : The Storyteller Overland MODE LT contains wiring that connects the secondary alternator to its auxiliary power system. This wiring includes: two 2/0 AWG wires and three wires for alternator control. Due to the potential improper routing of these wires, there is a risk of contact with the driver’s side CV axle shaft. STO is not aware of any injuries or property damage associated with this issue. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Contact between the wires and the CV axle shaft could cause physical damage to the insulation of the wires, potentially creating unprotected/frayed conductors. An unprotected/frayed conductor could cause an electrical short, Part 573 Safety Recall Report 22V-770 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 creating the risk of thermal damage, personal injury, or property damage. STO is not aware of any injuries or property damage associated with this issue. Description of the Cause : The wiring of the Mode LT connecting the secondary alternator system to the auxiliary power system has been inconsistently routed without sufficient measures taken to prevent the wires from coming into contact with the driver’s side CV axle shaft. Identification of Any Warning that can Occur : The secondary alternator system may not charge the auxiliary power system, or it may not charge consistently, while the vehicle is running. A customer may notice a burning smell and/or observe wiring damage near the driver’s side CV axle shaft. Involved Components : Component Name 1 : Volta External Harness Flex Fode Component Description : Volta External Harness Flex Fode Component Part Number : F3X-1142H0-00424 Component Name 2 : Custom Automated Services Universal Jumper Wire Ki Component Description : Universal Jumper Wire Kit Component Part Number : U3X-114211-00679 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : On September 29th, 2022, the auxiliary power system on a prototype MODE LT was identified as not charging from the secondary alternator. Upon investigation, STO technicians noticed wiring from the secondary alternator system to the auxiliary power system showed abrasion from contact with the driverโs side CV axle shaft. STOโs quality team then investigated vehicles on the production line and noticed inconsistent wire Part 573 Safety Recall Report 22V-770 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 routing. On October 10, 2022, an internal meeting was held to discuss these findings with STOโs internal safety committee, and the committee decided to issue a voluntary recall. Description of Remedy : Description of Remedy Program : The remedy to correct this defect will involve inspection of wiring for correct routing and to determine if any damage is present. If there is any damage, replacement wiring will be installed. Regardless of whether any damage is present, the wiring will be rerouted with heat-resistant ties away from the driverโs side CV axle shaft, and a heat shield will be added around the wiring as a redundancy. The remedy will be performed at no cost to the consumer at an STO authorized location. How Remedy Component Differs from Recalled Component : The remedy is primarily assembly process related; provided, however, the remedy components will involve additional wire protection as well as new routing/securing of the wires. Identify How/When Recall Condition was Corrected in Production : The recall condition was corrected in production with updated process instructions regarding wiring routing with proper fastening components and additional wire protection. This process will be verified on the production line. Recall Schedule : Description of Recall Schedule : Dealer and owner notification letters will be sent within the 60-day requirement. Planned Dealer Notification Date : OCT 13, 2022 – DEC 13, 2022 Planned Owner Notification Date : OCT 13, 2022 – DEC 13, 2022 * NR – Not Reported
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