February 28, 2024 NHTSA CAMPAIGN NUMBER: 24V158000
Inadequate Rear Axle Lubrication
Wheel lock-up or driveshaft separation can result in a loss of drive power. A disconnected driveshaft can also result in a roll away when the vehicle is in park without the parking brake applied. Any of these scenarios can increase the risk of a crash.
NHTSA Campaign Number: 24V158
Manufacturer Jayco
, Inc.
Components POWER TRAIN
Potential Number of Units Affected 82
Summary
Jayco, Inc. (Jayco) is recalling certain 2024 Jayco Granite Ridge, Solstice, Entegra Coach Condor, Expanse, and Expanse LI motorhomes. An inadequate amount of rear axle lubricant may cause rear axle tail bearing damage and seizure, which can result in wheel lock-up or driveshaft separation.
Remedy
Dealers will inspect the rear axle and replace the axle bearings or axle assembly as necessary, free of charge. Owner notification letters are expected to be mailed April 12, 2024. Owners may contact Jayco customer service at 1-800-283-8267. Jayco’s number for this recall is Ford 24V-102.
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.
Chronology :
Please refer to Ford Motor Company’s chronology on 24V-102. Ford or Jayco Inc. is not aware of any reports of injury related to this condition.
February 13, 2024 the Jayco Compliance team received information from Ford about recall 24S05 / NHTSA Recall 24V-102 regarding Inadequate Rear Axle Lubrication on certain 2023-2024 Model Year Transit Vehicles.
On February 19, 2024 Jayco’s Warranty Incident Review Committee (WIRC) reviewed the incident and elevated it to the Corrective Preventive Action Committee (CPAC). On February 21, 2024 (CPAC) decided to elevate the incident to the Safety Steering Committee (SSC).
On February 22, 2024 SSC voted to proceed with a Ford pass through chassis recall.
5 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| ENTEGRA | CONDOR | 2024 |
| ENTEGRA | EXPANSE | 2024 |
| ENTEGRA | EXPANSE LI | 2024 |
| JAYCO | GRANITE RIDGE | 2024 |
| JAYCO | SOLSTICE | 2024 |
2 Associated Documents
Defect Notice 573 Report
RCLRPT-24V158-5041.PDF 217.384KB
Recall Acknowledgement
RCAK-24V158-7715.pdf 646.181KB
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- Exceptional high and low temperature protection ranges from -15F to 410F for dependable year-round coverage
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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-158
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Jayco, Inc. FEB 28, 2024 NHTSA Recall No. : 24V-158 Manufacturer Recall No. : Ford 24V-102
Manufacturer Information :
Manufacturer Name : Jayco, Inc.
Address : 903 South Main Street
PO Box 460 Middlebury IN 46540 Company phone : 800-283-8267
Population :
Number of potentially involved : 82 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2024-2024 Jayco/Entegra Coach Condor, Expanse, Expanse LI, Granite Ridge, Solstice Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : GAS
Descriptive Information : Jayco obtained a list of affected VIN numbers from Ford Motor Company for their recall 24V-102. Jayco matched those VIN numbers to our production records.
Production Dates : JUL 31, 2023 – FEB 16, 2024 VIN Range 1 : Begin : 1FDRU8UG7PKB09812 End : 1FDRU8PG1PKB98773 ✔ Not sequential Description of Defect :
Description of the Defect : Ford Motor Company reported to Jayco Inc. that they are recalling certain 2023-2024 Model Year Transit Vehicles Equipped with a 9.75 Rear Axle. In the affected vehicles, insufficient rear axle lubricant fill volume may result in an inadequate coating of the rear axle pinion bearing, potentially leading to overheat and bearing seizure. Bearing seizure may lead to rear wheel lock-up and driveshaft separation from the rear axle.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : In the event of rear axle bearing seizure, customers may experience rear
wheel lock-up and possible driveshaft separation, resulting in loss of vehicle control or loss of vehicle motive power. Driveshaft separation may result in unintended vehicle movement while the vehicle is in Park if the parking brake is not applied. These conditions increase the risk of crash or injury.
Description of the Cause : A revised rear axle design was introduced into production with insufficient lubrication volume. The inadequate volume of rear axle lubricant was due to a
change in the static level of axle lubricant in the revised rear axle design. Part 573 Safety Recall Report 24V-158 Page 2 Identification of Any Warning
that can Occur : Customers may observe rear axle fluid leaks while stationary and may experience grinding noise and vibration from the rear axle while driving. Involved Components : Component Name 1 : Single Rear Wheel Axle Assembly
Component Description : 3.73 Conventional Differential Single Rear Wheel Component Part Number : MK4W-4001-BD Component Name 2 : Single Rear Wheel Axle Assembly
Component Description : 3.73 Limited Slip Differential Single Rear Wheel Component Part Number : MK4W-4001-CD Component Name 3 : Single Rear Wheel Axle Assembly
Component Description : 4.10 Limited Slip Differential Single Rear Wheel Component Part Number : MK4W-4001-DD Component Name 4 : Single Rear Wheel Axle Assembly
Component Description : 3.73 Limited Slip Differential Single Rear Wheel Component Part Number : MK4W-4001-GC Component Name 5 : Single Rear Wheel Axle Assembly
Component Description : 4.10 Limited Slip Differential Single Rear Wheel Component Part Number : MK4W-4001-HC Component Name 6 : Dual Rear Wheel Axle Assembly
Component Description : 3.73 Conventional Differential Single Rear Wheel Component Part Number : JK4W-4001-DE The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-158 Page 3 Component Name 7 : Dual Rear Wheel Axle Assembly
Component Description : 3.73 Limited Slip Differential Single Rear Wheel Component Part Number : JK4W-4001-BE Component Name 8 : Dual Rear Wheel Axle Assembly
Component Description : 4.10 Limited Slip Differential Single Rear Wheel Component Part Number : JK4W-4001-AE Component Name 9 : Dual Rear Wheel Axle Assembly
Component Description : 3.73 Limited Slip Differential Single Rear Wheel Component Part Number : LK4W-4001-ABE Component Name 10 : Dual Rear Wheel Axle Assembly
Component Description : 3.73 Limited Slip Differential Single Rear Wheel Component Part Number : LK4W-4001-AFD Component Name 11 : Dual Rear Wheel Axle Assembly
Component Description : 4.10 Limited Slip Differential Single Rear Wheel Component Part Number : LK4W-4001-ADE Supplier Identification : Component Manufacturer
Name : Sterling Axle Plant Address : 39000 Mound Road
Sterling Heights Michigan 48310
Country : United States Chronology :
Please refer to Ford Motor Company’s chronology on 24V-102. Ford or Jayco Inc. is not aware of any reports of The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-158
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
injury related to this condition.
February 13, 2024 the Jayco Compliance team received information from Ford about recall 24S05 / NHTSA Recall 24V-102 regarding Inadequate Rear Axle Lubrication on certain 2023-2024 Model Year Transit Vehicles. On February 19, 2024 Jayco’s Warranty Incident Review Committee (WIRC) reviewed the incident and elevated it to the Corrective Preventive Action Committee (CPAC). On February 21, 2024 (CPAC) decided to elevate the incident to the Safety Steering Committee (SSC).
On February 22, 2024 SSC voted to proceed with a Ford pass through chassis recall.
Description of Remedy :
Description of Remedy Program : Owners will be notified by mail and instructed to take their vehicle to a
Ford or Lincoln dealer to have their rear axle inspected. If any axles experience symptoms consistent with pending failure, the full axle assembly will be replaced. If metal shavings are present on the axle fill plug magnet, the fluid will be washed and the axle bearings will be replaced. If metal shavings are not present, dealers will add additional axle lubricant to the rear differential. There will be no charge for this service.
Ford provided the general reimbursement plan for the cost of remedies paid for by vehicle owners prior to notification of a safety recall in May 2023. The ending date for reimbursement eligibility is estimated to be March 15, 2024.
Ford Motor Company will be reporting the quarterly completion rates to NHTSA. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : The remedy rear axle (MK4W/JK4W/LK4W-4001-A/B/C/D/G/H) will contain the correct lubricant level to avoid a potential bearing seizure.
NR Recall Schedule :
Description of Recall Schedule : Jayco will notify its dealers and affected retail owners.
Planned Dealer Notification Date : APR 12, 2024 – APR 12, 2024
Planned Owner Notification Date : APR 12, 2024 – APR 12, 2024
* NR – Not Reported
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