Improperly Secured Ceiling Panels – 2019-2022 Starcraft Prodigy School Buses

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RECALL 23V254 REMEDY INSTRUCTIONS
Make(s): STARCRAFT BUS
Model(s): PRODIGY
Model Year(s): 2019 – 2021
Concern:
A non-compliance to “FMVSS 221 Joint
Strength” was found on two interior panel
pieces removed from the ceiling of the bus.
Repair Code: RC-090-00-03-004322
Allotted Time: .67 HRS.
Inspection Code: RC-090-00-05-004321
Allotted Time: .17 HRS.
Photo(s) Required: NO
Prior Authorization Required: YES
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.
PARTS REQUIRED:
28 – #10-16 X 1” SD SQUARE #2
4 – WOOD SHIMS
1 – SIKA 3131 ADHESIVE
INSPECTION PROCESS:
STEP 1: REMOVE ALL SCREWS FROM INTERIOR CEILING PANEL SEAMS;
STEP 2: TRY TO SEPARATE THE PANELS, ENSURING NOT TO DAMAGE CEILING SURFACE;
STEP 3: IF THE PANEL IS ADHERED AND DOES NOT SEPARATE, THE INSPECTION IS COMPLETE AND THE UNIT IS NOT IN NEED OF THE
REPAIR;
• CLAIM THE REPAIR CODE
• IF THE PANELS ARE ABLE TO BE SEPARATED PROCEED TO REPAIR PROCEDURE BELOW.
REPAIR PROCESS:
CONTACT STARCRAFT WARRANTY FOR AUTHORIZATION AND TO ALSO ORDER THE PARTS KIT AS NEEDED;
STEP 4: REMOVE THE SIDE ACCESS PANEL SCREWS AND REMOVE THE ACCESS PANELS;
STEP 5: PLACE MASKING TAPE ALONG FRONT EDGE OF SEAM TO MAKE IT EASIER TO CLEAN ACCESS ADHESIVE FROM STEP 8;
STEP 6: PLACE A SMALL SPACER OR WEDGE BETWEEN THE TWO PANELS TO CREATE ADEQUATE SPACE FOR ADHESIVE
APPLICATION;
STEP 7: PLACE A ¼” BEAD OF TWO PART SIKA 3131 PRODUCT ALONG THE ENTIRE UPPER SEAM; ½” FROM THE LEADING EDGE OF
THE PANEL;
STEP 8: RE-SEAT THE ORIGINAL SCREWS BACK INTO THE PANEL(S), ADD THE ADDITIONAL SCREWS FROM THE KIT IN BETWEEN EACH OF THE EXISTING SCREWS AND PULL THE MASKING TAPE OFF OF CEILING;
STEP 9: RE-ATTACH THE SIDE ACCESS PANELS;
STEP 10: BE SURE TO WIPE ANY EXCESS ADHESIVE FROM THE SEAM IMMEDIATELY AS THE ADHESIVE WILL BE EXTREMELY DIFFICULT TO REMOVE ONCE IT IS CURED;
STEP 11: CLAIM REPAIR CODE.
PHOTOS ON FOLLOWING PAGE FOR INSPECTION / REMEDY
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RECALL 23V254 REMEDY INSTRUCTIONS
Make(s): STARCRAFT BUS
Model(s): PRODIGY
Model Year(s): 2019 – 2021
Concern:
A non-compliance to “FMVSS 221 Joint
Strength” was found on two interior panel
pieces removed from the ceiling of the bus.
Repair Code: RC-090-00-03-004322
Allotted Time: .67 HRS.
Inspection Code: RC-090-00-05-004321
Allotted Time: .17 HRS.
Photo(s) Required: NO
Prior Authorization Required: YES
Part(s) Kit Number: N/A
Part(s) Return: N/A
INSPECTION/REMEDY:
1
2
5
4
8
Place provided screws 2.5” from each existing screws

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IMPORTANT SAFETY RECALL
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April 2023
This Notice applies to your vehicle VIN listed above.
Dear Forest River Customer:
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 National Traffic and Motor Vehicle Safety Act. Forest River has decided that a noncompliance, which relates to the motor vehicle safety, exists in certain 2019-2022 Starcraft Prodigy School Buses and fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 221, “Joint Strength.” This is to inform you that your vehicle may be non-compliant with the requirements of the Motor Vehicle Safety Regulations and that the non-compliance could affect the safety of a person.
WHAT IS THE DEFECT/NONCOMPLIANCE?
A non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
Improperly secured ceiling panels may not adequately protect the passengers in the event of a crash, increasing the risk of injury.
WHAT IS FOREST RIVER AND OUR DEALERSHIPS GOING TO DO?
The remedy for this recall is included with this notification. Forest River has notified dealerships of this recall and have provided them with remedy instructions to secure the ceiling panels. 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 .67 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:
Starcraft Bus
Forest River Bus, LLC
Attn: WARRANTY MANAGER
2367 Century Drive
Goshen, IN 46528
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
BUILDING 11
423 N MAIN ST
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 23V254
CANADA RECALL: N/A
FR ID: 05-1621
<<VIN>>
<<OWNER NAME/DEALERNAME>>
<<ADDRESS>>
<<CITY>>, <<ST>> <<ZIP-XXX>>
O Integrity
O Safety
O Quality
O Customer Service
IMPORTANT SAFETY RECALL
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What if you no longer own this vehicle?
If you no longer own this vehicle and have the address for the current owner, please forward this letter to the new owner within 10 working days of receiving this notice. You have received this letter because government regulations require that a notification is sent to the last known owner of record. Our records indicate that you are the current owner.
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.
MAY FOREST RIVER ASSIST YOU FURTHER?
If you have difficulties getting your vehicle repaired, please contact your Forest River Representative listed below:
CONTACT
PHONE
CUSTOMER SERVICE
(800) 348-7440
If you are still having difficulty getting your vehicle repaired in a reasonable amount of time or without change, you may write to the following address:
For US Owners Please Contact:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Ave, S.E.
Washington, D.C. 20590
Or you may call the toll free Vehicle Safety Hotline at 1-888-327-4236 or (TTY: 1-800-424-9153).
Or visit www.safercar.gov and search;
Recall ID: 23V254
Sincerely,
Forest River, Bus, LLC.
Office of Corporate Compliance

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IMPORTANT SAFETY RECALL
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April 2023
Pursuant to USC49CFR §577.13 – Notification to Dealerships and Distributors – Paragraph B
“It is a violation of Federal Law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by the notification under a sale or lease until the defect or noncompliance is remedied. Substantial civil penalties apply to violations of this law.”
–Forest River motorized and towable products are contained in this section-
CANADA: Pursuant to the Canadian Motor Vehicle Safety Act, section 5
Companies who sell new non-complying vehicles may be in violation of the Motor Vehicle Safety Act. Substantial penalties apply to violations of this law. This notice is being sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person.
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 National Traffic and Motor Vehicle Safety Act. Forest River has decided that a noncompliance, which relates to the motor vehicle safety, exists in certain 2019-2022 Starcraft Prodigy School Buses and fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 221, “Joint Strength.” This is to inform you that your vehicle may be non-compliant with the requirements of the Motor Vehicle Safety Regulations and that the non-compliance could affect the safety of a person.
The identified VIN referenced in the attached document(s).
The designated Date range of production is 3/11/2019 through 5/15/2020.
WHAT IS THE DEFECT/NONCOMPLIANCE?
A non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus.
EVALUATION OF THE RISK TO THE VEHICLE AND OPERATOR(S) RELATED TO THE RECALL.
Improperly secured ceiling panels may not adequately protect the passengers in the event of a crash, increasing the risk of injury.
DEALERS WHAT SHOULD YOU DO?
The remedy for this recall can be found on Dealer Connect.
DEALER REPAIR CODES: Dealer Connect
UNITED
STATES
CANADA
REPAIR
CODE
DESCRIPTION
ALLOWABLE HOUR(S)
23V254
N/A
RC-090-00-05-004321
PERFORM INSPECTION
.17 HRS
23V254
N/A
RC-090-00-03-004322
PERFORM INSPECTION AND REMEDY
.67 HRS
HELPFUL CONTACT INFORMATION:
CONTACT
PHONE
CUSTOMER SERVICE
(800) 348-7440
The Recall shall be considered the utmost priority to remedy the 2019-2022 Starcraft Prodigy School Buses in question. The retail consumer shall not be charged any amount of monies for remedy to their 2019-2022 Starcraft Prodigy School Buses listed under this Recall.
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
BUILDING 11
423 N MAIN ST
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 23V254
CANADA RECALL: N/A
FR ID: 05-1621
<<DEALERNAME>>
<<ADDRESS>>
<<CITY>>, <<ST>> <<ZIP-XXX>>
O Integrity
O Safety
O Quality
O Customer Service
IMPORTANT SAFETY RECALL
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If your dealership has already performed the remedy to 2019-2022 Starcraft Prodigy School Buses, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s). If the remedy needs to be performed on an out of warranty 2019-2022 Starcraft Prodigy School Buses in which the VIN falls under as stated in the identified VIN listing, your dealership is entitled to the reimbursement as stated above by filing a claim using the indicated repair code(s).
Notice:
In no manner shall a Forest River Product Owner or Coachmen Product Owner be charged any fee(s) for scheduling, conduction or completion of the recall. Additionally, all dealership(s) that are Forest River and/or Coachmen dealership(s) are Federally Mandated to perform the recall once presented with this recall whether by the Owner or Dealership receipt of this letter, without denial of service to the Owner. Lastly, denial of a remedy for this recall is a Federal Violation punishable by law resulting substantial fines and/or civil penalties.
Federal Regulation requires that any lessor receiving this Recall must forward a copy of this notice to the lessee within ten days. If your dealership no longer owns this vehicle, please inform the Warranty Manager of the product listed above of the change of ownership.
Sincerely,
Forest River, Bus, LLC.
Office of Corporate Compliance

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-254
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River Bus, LLC APR 07, 2023 NHTSA Recall No. : 23V-254 Manufacturer Recall No. : 05-1621 Manufacturer Information :
Manufacturer Name : Forest River Bus, LLC Address : 2367 Century Drive
Goshen IN 46528
Company phone : (800) 348-7440
Population :
Number of potentially involved : 29 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2019-2022 Forest River Bus LLC Starcraft Prodigy School Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Using manufacturing records, the manufacturing plant identified all School Buses affected by this FMVSS 221 violation.
Starcraft Prodigy Transit Buses – 29 Production Dates : MAR 11, 2019 – MAY 15, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : A non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus. FMVSS 1 : 221 – School bus body joint strength FMVSS 2 : NR
Description of the Safety Risk : The subject vehicles do not meet the joint strength requirements of FMVSS
221 and may not adequately protect passengers in the event of a crash.
Description of the Cause : Panel joints of the ceiling did not receive adequate adhesive in the proper location. Identification of Any Warning
that can Occur : None
Involved Components : Part 573 Safety Recall Report 23V-254 Page 2 Component Name 1 : Ceiling Panel Component Description : Ceiling Panel Component Part Number : N/A Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
In 2019, NHTSA purchased a Starcraft school bus (Prodigy) single rear wheel unit to verify FMVSS compliance. During this testing process in March, 2023, a non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus.
NHTSA engineer Daniel Lind informed Don Hasty of the non-compliance on March 22nd, 2023. The discussion over the results and reports sent led to further investigation on the application of the adhesive failure of the test component substrates. The adhesive on the test vehicle panels was improperly applied causing the failure to the FMVSS 221 test procedure. On March 23rd, 2023, Don contacted Daniel to inform him that the data had been received and the review process had been started. Don found that the suspect bus and 28 others may not have had the adhesive in the appropriate location on the panels. Based on the line assembly process flow these units will be recalled and inspected to ensure the adhesive was properly applied on both previously built units and units built after the subject vehicle. On April 6, 2023, Forest Rivers Office of Corporate Compliance was informed of the failed test results. On April 7, 2023, Forest Rivers Corporate Recall Committee was informed of the test results and voted to recall. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-254
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Forest River will provide all parts and labor free of charge to Consumers
and Dealers. An authorized Forest River dealer will need to perform the remedy. Owners will be instructed to take their bus to their local dealership and have it inspected for the application of the adhesive. If the panel pieces do not have the adhesive properly applied the panels will be able to separate. If separation occurs, adhesive will have to be re-applied and the panels fastened back together.
What is the Forest River Customer Service Phone Number? (800) 348-7440 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:
Starcraft Bus
Forest River Bus, LLC
Attn: WARRANTY MANAGER
2367 Century Drive
How Remedy Component Differs from Recalled Component :
The panels will not be able to be separated once the adhesive has cured. Affected Component – Ceiling Panel
Component Part Number – N/A Identify How/When Recall Condition was Corrected in Production : The production line flow was altered to consolidate the processes in each station to accommodate all school bus procedures to be consistent. Recall Schedule :
Description of Recall Schedule : Forest River has the utmost urgency in our recalls. Forest River will send
suspected VIN numbers to our third party vendor that is licensed to pull data on the current owner of the vehicles (as needed) once a formal NHTSA I.D. is provided. Forest River intends on pushing the mailing out as soon as NHTSA provides any correction(s) and an Acknowledgement Letter.
Planned Dealer Notification Date : MAY 17, 2023 – MAY 17, 2023
Planned Owner Notification Date : MAY 17, 2023 – MAY 17, 2023
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-254
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River Bus, LLC APR 12, 2023 NHTSA Recall No. : 23V-254 Manufacturer Recall No. : 05-1621 Manufacturer Information :
Manufacturer Name : Forest River Bus, LLC Address : 2367 Century Drive
Goshen IN 46528
Company phone : (800) 348-7440
Population :
Number of potentially involved : 29 Estimated percentage with defect : 100 %
Vehicle Information :
Vehicle 1 : 2019-2022 Forest River Bus LLC Starcraft Prodigy School Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Using manufacturing records, the manufacturing plant identified all School Buses affected by this FMVSS 221 violation.
Starcraft Prodigy Transit Buses – 29 Production Dates : MAR 11, 2019 – MAY 15, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : A non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus. FMVSS 1 : 221 – School bus body joint strength FMVSS 2 : NR
Description of the Safety Risk : Improperly secured ceiling panels may not adequately protect the passengers in the event of a crash, increasing the risk of injury.
Description of the Cause : Panel joints of the ceiling did not receive adequate adhesive in the proper location. Identification of Any Warning
that can Occur : None
Involved Components : Part 573 Safety Recall Report 23V-254 Page 2 Component Name 1 : Ceiling Panel Component Description : Ceiling Panel Component Part Number : N/A Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
In 2019, NHTSA purchased a Starcraft school bus (Prodigy) single rear wheel unit to verify FMVSS compliance. During this testing process in March, 2023, a non-compliance to “FMVSS 221 Joint Strength” was found on two interior panel pieces removed from the ceiling of the bus.
NHTSA engineer Daniel Lind informed Don Hasty of the non-compliance on March 22nd, 2023. The discussion over the results and reports sent led to further investigation on the application of the adhesive failure of the test component substrates. The adhesive on the test vehicle panels was improperly applied causing the failure to the FMVSS 221 test procedure. On March 23rd, 2023, Don contacted Daniel to inform him that the data had been received and the review process had been started. Don found that the suspect bus and 28 others may not have had the adhesive in the appropriate location on the panels. Based on the line assembly process flow these units will be recalled and inspected to ensure the adhesive was properly applied on both previously built units and units built after the subject vehicle. On April 6, 2023, Forest Rivers Office of Corporate Compliance was informed of the failed test results. On April 7, 2023, Forest Rivers Corporate Recall Committee was informed of the test results and voted to recall. On April 12, 2023, as per NHTSA’s acknowledgment letter, amended the safety risk to include the risk of injury. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-254
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Forest River will provide all parts and labor free of charge to Consumers
and Dealers. An authorized Forest River dealer will need to perform the remedy. Owners will be instructed to take their bus to their local dealership and have it inspected for the application of the adhesive. If the panel pieces do not have the adhesive properly applied the panels will be able to separate. If separation occurs, adhesive will have to be re-applied and the panels fastened back together.
What is the Forest River Customer Service Phone Number? (800) 348-7440 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:
Starcraft Bus
Forest River Bus, LLC
Attn: WARRANTY MANAGER
2367 Century Drive
How Remedy Component Differs from Recalled Component :
The panels will not be able to be separated once the adhesive has cured. Affected Component – Ceiling Panel
Component Part Number – N/A Identify How/When Recall Condition was Corrected in Production : The production line flow was altered to consolidate the processes in each station to accommodate all school bus procedures to be consistent. Recall Schedule :
Description of Recall Schedule : Forest River has the utmost urgency in our recalls. Forest River will send
suspected VIN numbers to our third party vendor that is licensed to pull data on the current owner of the vehicles (as needed) once a formal NHTSA I.D. is provided. Forest River intends on pushing the mailing out as soon as NHTSA provides any correction(s) and an Acknowledgement Letter.
Planned Dealer Notification Date : MAY 17, 2023 – MAY 17, 2023
Planned Owner Notification Date : MAY 17, 2023 – MAY 17, 2023
* NR – Not Reported

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