23E096 – Awning May Extend Unintentionally – Carefree Freestyle Gearbox Housing

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23E-096
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Carefree Of Colorado DEC 21, 2023 NHTSA Recall No. : 23E-096 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Carefree Of Colorado Address : 2145 W 6th Avenue
Broomfield CO 80020
Company phone : 800-621-2617
Population :
Number of potentially involved : 8,115 Estimated percentage with defect : 1 %
Equipment Information : Brand / Trade 1 :
Model : Carefree of Colorado Freestyle Part No. : 015933-001 Size : NR Function : NR
Descriptive Information : The units affected by this notice are based on the time period of the production dates for the component in question. There are approximately 8,115 units potentially affected by the issue of concern.
Production Dates : FEB 27, 2020 – NOV 01, 2021
Description of Defect :
Description of the Defect : There is a potential for cracks to develop in the gearbox housing. In a fraction of a percent of units, a gearbox housing has been observed to show a crack that may develop into a fracture. As a result of such fracture is a potential for release of the awning brake under certain in-use conditions.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : An awning that extends unintentionally while the motor home is in motion
could be a distraction and/or present a road hazard to the vehicle driver or oncoming traffic, which can increase the risk of a crash.
Description of the Cause : NR
Identification of Any Warning
that can Occur :
NR
Involved Components : Part 573 Safety Recall Report 23E-096 Page 2 Component Name : Motor Assembly, Small Box, 12V DC, Left Hand
Component Description : A motor which rolls and unrolls the awning, and holds the awning closed when not in use, located on the left hand side of the awning.
Component Part Number : 015933-001 Supplier Identification : Component Manufacturer
Name : ICSN
Address : 521 Princeland Court
Corona California 928789 Country : United States Chronology :
On or about August 31, 2022 the Company received a report of an awning deployment with a suspected crack in the gearbox housing. The company promptly began an investigation, which ultimately led to the Company submitting a safety recall report and implementing NHTSA Campaign Number 22E-094. Based on information available to the Company at that time, the Company believed the issue of concern was limited to certain Freestyle right-hand gearbox motor housing assemblies. As the Company has monitored the implementation of the remedy for the NHTSA Campaign Number 22E-094 and upon further investigation, the Company has been made aware of cracks occurring in certain Freestyle left-hand gearbox motor housing assemblies. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23E-096 Page 3 Description of Remedy :
Description of Remedy Program : The Company intends to coordinate the remedy of units identified in this
report in conjunction with Winnebago, Coachmen RV, Thor Moto Coach and Jayco. The Company will apply the remedy from NHTSA Campaign Number 22E-094, by coordinating the installation of additional material (which the Company refers to as a “wedge”) intended to support the internal components inside certain Freestyle left-handed gearbox motor housing assemblies in production from February 27, 2020 to November 1, 2022.
To avoid end-user confusion, the Company does not plan to notify Winnebago customers separately about this issue as Winnebago is currently implementing its own recall (NHTSA Recall Number 23V-694) for awning deployments affecting the same population of its vehicles. The Company will continue to provide support and coordinate with Winnebago to ensure the remedy is carried out consistenly with the Company’s other customers. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : See above On November 1, 2022. the Company issued a stop shipment and stop production order that applied to right-hand gearbox motor housing assemblies at issue in NHTSA Campaign Number 22E-094. The Company has since added the wedge as part of all right-hand and left-hand gearbox motor housig assemblies in initial production. Recall Schedule :
Description of Recall Schedule : The Company will promptly communicate with OEM’s to identify
applicable dealers and will then initiate its campaign through dealers to those customers with the potentially affected configuration.
Planned Dealer Notification Date : DEC 29, 2023 – NR Planned Owner Notification Date : FEB 06, 2024 – NR Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Winnebago Industries Address : P.O. Box 152
Forest City IA 50436 Country : US Company Phone : NR The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23E-096
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Name : Coachmen RV Address : 423 N Main Street Middlebury IN 46540 Country : US Company Phone : NR Name : Thor Motor Coach Address : 701 County Road 15
Elkhart IN 46516 Country : US Company Phone : NR Name : jayco Address : 903 S. Main Street Middlebury IN 46540 Country : US Company Phone : NR
* NR – Not Reported

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