05-1741 – Unsecured Brake Line May Become Damaged – 2024 Elkhart Coach ELKC Transit Buses

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-136
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River Bus, LLC FEB 23, 2024 NHTSA Recall No. : 24V-136 Manufacturer Recall No. : 05-1741 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 : 5
Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2024-2024 Forest River Bus LLC Elkhart Coach Transit Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by manufacturing records provided by the supplier.
2024 ELKHART COACH-ELKC EK1013 2
Production Dates : FEB 06, 2024 – FEB 15, 2024
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The brake lines may not be attached to the driver’s side frame rail.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : If the brake lines touch the frame rail, the lines could develop a hole causing loss of brake pressure. This condition may lead to a crash.
Description of the Cause : Vendor Error
Identification of Any Warning
that can Occur :
None
Involved Components : Part 573 Safety Recall Report 24V-136 Page 2 Component Name 1 : Brake Line(s) Rear Component Description : Brake Line(s) Rear Component Part Number : N/A Supplier Identification : Component Manufacturer
Name : Lippert Components Inc Address : PO BOX 2888
Elkhart Indiana 46515
Country : United States Chronology :
On February 20, 2024, Forest River’s Office of Corporate Compliance (“OCC”) was notified by its supplier, Lippert Components, that when stretching the chassis, P-Clamps may not have been installed to hold the brake lines in place. OCC opened a research item. On February 23, 2024, Forest Rivers Corporate Recall Committee voted to recall. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-136
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 to repair the rear brake lines.
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.
Attn: WARRANTY MANAGER
2367 Century Drive
Goshen, IN 46528
How Remedy Component Differs from Recalled Component :
Involved Component – Brake Line(s) Rear
Replacement Component – 2 – P-Clamps, Rubber Cushion, and Self-Tapping Fasteners The brake lines will now be secured properly to ensure they do not come in contact with the frame rail.
Identify How/When Recall Condition was Corrected in Production :
The week of February 20, 2024, the supplier began inspecting and installing P-Clamps on any affected vehicle within the Forest River Bus holding yard. 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 : APR 01, 2024 – APR 01, 2024
Planned Owner Notification Date : APR 01, 2024 – APR 01, 2024
* NR – Not Reported

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Rev: 02.27.2024 Page 1 CCD-0008651
SECURING BRAKE LINES TO CHASSIS
TSB Number: 164-001-2024
Product: Brakes
Date: February 27, 2024
Purpose
This document outlines repairing a specific list of units that may have brake lines unsecured to the chassis.
The fix includes attaching P-clamps to secure brake lines to the chassis.
Safety
This document provides general instructions. Many variables can change the circumstances of any
procedure, i.e. the degree of difficulty involved in the service operation and the ability level of the individual
performing the operation. This document cannot begin to plot out procedures for every possibility, but will
provide the general instructions for effectively installing, removing or servicing the system. In the event the
skill level required is too advanced or the procedure too difficult, a certified technician should be consulted
before performing the necessary operation. Failure to correctly install, remove or service the system may
result in voiding the warranty, inflicting injury or even death.
The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause
death, serious personal injury, severe product and/or property damage if not performed safely and
within the parameters set forth in this document.
The “CAUTION” symbol above is a sign that a procedure has a safety risk involved and may cause
personal injury, product and/or property damage if not performed safely and within the parameters
set forth in this document.
All industrial safety standards must be followed when performing work identified in this procedure.
Resources Required
• Self-tapping screws, PN 2024006671
• Rubber P-clamps, PN 2023136417
• Cordless or electric drill or screw gun
• 3/16″ drill bit
Rev: 02.27.2024 Page 2 CCD-0008651
SECURING BRAKE LINES TO CHASSIS
TSB Number: 164-001-2024
Product: Brakes
Date: February 27, 2024
Instructions
1. Identify manufacturing defect on the inside of the driver’s side frame rail, just under the rear cab
mount (Figs. 1A and 2A).
2. Drill pilot hole in the chassis (3/16” drill in one place) for a self-tapping screw between the brake lines.
This will be between the two brake line couplers, 4” from top of frame rail and 4.5” from the front of
square hole (Fig. 3).
NOTE: Picture is from the inside of the drivers side frame rail.
3. Attach P-clamps around each line making sure the holes are to the center (Fig. 4A).
Fig. 1 Fig. 2
Fig. 3 Fig. 4
Square Hole
4.5″
4″
A
A
A
A
A
A
Rev: 02.27.2024 Page 3 CCD-0008651
TSB Number: 164-001-2024
Product: Brakes
Date: February 27, 2024
As a supplier of a broad array of highly-engineered components in the recreation and transportation product markets, safety, education and customer satisfaction are
our primary concerns. Should you have any questions, please do not hesitate to contact us at 432-LIPPERT (432-547-7378) or by email at [email protected].
Self-help tips, technical documents, product videos and a training class schedule are available at lippert.com or by downloading the LippertNOW app.
SECURING BRAKE LINES TO CHASSIS
4. Screw the self-tapping screw through both holes of the brake line clamps (Figs. 5A and 6A).
NOTE: Fig. 7 shows the finished repair.
Fig. 5 Fig. 6
Fig. 7 Fig. 8
A
A
NOTE: Make sure the brake lines that run over the driver’s side frame rail are not touching the frame rail.
Fig. 8 shows the correct placement of the brake lines. If the brake lines touch the frame rail, the lines
could develop a hole causing loss of brake pressure.

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IMPORTANT SAFETY RECALL
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March 2024
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-
Forest River has decided that a safety defect exists in certain 2024 Elkhart Coach, Glaval Universal, and Starcraft Allstar Transit Buses. Forest River is recalling the defective model(s) to ensure the safety of our future retail consumers and your dealership. Forest River apologizes for any inconvenience this action may cause your dealership; however, safety continued satisfaction and our commitment to building great products are of the utmost importance to Forest River.
The identified VIN is referenced in the attached document(s).
The designated Date range of production is 02/06/2024 through 02/15/2024.
DEFECT/NONCOMPLIANCE:
The brake lines may not be attached to the driver’s side frame rail.
EVALUATION OF RISK:
If the brake lines touch the frame rail, the lines could develop a hole causing loss of brake pressure. This condition may lead to a crash.
SERVICE PROCEDURE:
Dealership Service Department procedures can be found on Dealer Connect. Service Campaign# B000038
HELPFUL CONTACT INFORMATION:
CONTACT
PHONE
FOREST RIVER BUS CUSTOMER SERVICE
(800) 348-7440
LIPPERT CUSTOMER SERVICE
(574) 537-8900
The Recall shall be considered the utmost priority to remedy the 2024 Elkhart Coach, Glaval Universal, and Starcraft Allstar Transit Buses in question. The retail consumer shall not be charged any amount of monies for remedy to their 2024 Elkhart Coach, Glaval Universal, and Starcraft Allstar Transit Buses listed under this Recall.
If your dealership has already performed the remedy to 2024 Elkhart Coach, Glaval Universal, and Starcraft Allstar Transit 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 2024 Elkhart Coach, Glaval Universal, and Starcraft Allstar Transit 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.
DEPARTMENT OF COMPLIANCE
VEHICLE SAFETY AND RECALL MANAGEMENT
Po Box 30
MIDDLEBURY, INDIANA 46540-9218
NHTSA RECALL: 24V136
CANADA RECALL: N/A
FR ID: 05-1741
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IMPORTANT SAFETY RECALL
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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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