05-1782 – Inadequate Roof Panel Joint Strength – 2010-2020 Forest River Starcraft Prodigy, Quest, & 2013 Rondak School Buses

Non-Compliance Recall 573 Report

RCLRPT-24V370-8909.PDF 215.832KB

Recall Acknowledgement

RCAK-24V370-9256.pdf 645.937KB

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-370
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Forest River Bus, LLC MAY 24, 2024 NHTSA Recall No. : 24V-370 Manufacturer Recall No. : 05-1782 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 : 854 Estimated percentage with defect : 5 %
Vehicle Information :
Vehicle 1 : 2010-2020 Forest River Bus LLC Starcraft MFSAB/Prodigy School Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by manufacturing records which identified school buses involved. The recall scope includes all vehicles produced using the certification test results that correlate to the March 30, 2011 build specifications for the exterior roof joint and ends with the date on which Starcraft stopped producing school buses.
See Attached Spreadsheet with Model and Quantity. Production Dates : MAR 30, 2011 – JAN 30, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2010-2020 Forest River Bus LLC Starcraft Quest School Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by manufacturing records which identified school buses involved. The recall scope includes all vehicles produced using the certification test results that correlate to the March 30, 2011 build specifications for the exterior roof joint and ends with the date on which Starcraft stopped producing school buses.
See Attached Spreadsheet with Model and Quantity. Production Dates : MAR 30, 2011 – JAN 30, 2020
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 24V-370 Page 2 Vehicle 3 : 2013-2013 Forest River Bus LLC Starcraft MFSAB/Rondak School Buses Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : The scope was determined by manufacturing records which identified school buses involved. The recall scope includes all vehicles produced using the certification test results that correlate to the March 30, 2011 build specifications for the exterior roof joint and ends with the date on which Starcraft stopped producing school buses.
See Attached Spreadsheet with Model and Quantity. Production Dates : NOV 16, 2012 – NOV 27, 2012
VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : The subject vehicles may not meet the FMVSS 221 joint strength requirements at the exterior front roof joint. FMVSS 1 : 221 – School bus body joint strength FMVSS 2 : NR
Description of the Safety Risk : If the joint strength requirements of FMVSS 221 are not met, passengers may not be adequately protected, increasing the risk of injury in the event of a crash.
Description of the Cause : NR Identification of Any Warning
that can Occur : None Involved Components : Component Name 1 : Exterior Roof Panels Component Description : Exterior Roof Panels Component Part Number : N/A Supplier Identification : Component Manufacturer Name : NR The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-370 Page 3 Address : NR
NR Country : NR Chronology :
During FMVSS 221 compliance testing conducted by KARCO at NHTSA’s request on April 20, 2023, an apparent noncompliance was found on a Forest River Bus Quest school bus. The apparent non-compliance involved the exterior front roof panel seam of the school bus. NHTSA notified Forest River Bus of the noncompliance on June 6, 2023, and Forest River Bus opened a research item into the issue including a review of the test report, photographs, and a review of Forest River’s compliance testing records. Forest River Bus and NHTSA continued correspondence numerous times via conference calls and email exchanges between June 6, 2023, through May 2024. Although Forest River disagrees with KARCO’s testing results and noted several inconsistencies in the manner in which KARCO conducted its compliance testing, on May 21, 2024, Forest River’s Corporate Recall Committee decided to conduct a recall to address this issue. Description of Remedy :
Description of Remedy Program : The remedy for this recall is under development. Forest River will amend
this recall to reflect the remedy once it is available. 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 (5A) 2367 Century Drive
Goshen, IN 46528 How Remedy Component Differs from Recalled Component : Affected Component – Exterior Roof Panels Replacement Component – TBD Identify How/When Recall Condition was Corrected in Production : Manufacturing of these school buses ceased in 2020. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-370
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
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 which 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 to push the mailing out as soon as NHTSA provides any correction(s) and an acknowledgment letter.
Planned Dealer Notification Date : JUL 03, 2024 – JUL 03, 2024
Planned Owner Notification Date : JUL 03, 2024 – JUL 03, 2024
* NR – Not Reported

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