19-349 – Tire may Contact Underside of Floor – 2018-2019 Dutchmen Kodiak Recreational Trailers

March 25, 2019

Tire may Contact Underside of Floor

Tire failure can cause a loss of vehicle control, increasing the risk of crash.

 

NHTSA Campaign Number: 19V231

Manufacturer Keystone RV Company

Components TIRES

Potential Number of Units Affected 561

 

Summary

Keystone RV Company (Keystone) is recalling certain 2018-2019 Dutchmen Kodiak recreational trailers, models 255BHSL and 283BHSL, equipped with 15-inch tires. The tire clearance to the floor may be insufficient, allowing the tire to contact the underside of the floor, possibly resulting in tire failure.

 

Remedy

Keystone has notified owners, and dealers will install a suspension lift kit, free of charge. The recall began on April 12, 2019. Owners may contact Keystone customer service at 1-866-425-4369. Keystone’s number for this recall is 19-349.

 

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.safercar.gov.

 

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4/11/19

Keystone RV Company

SAFETY ADVISORY # 19-349

Kodiak Tire Clearance

Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that the vehicles in the recall population may not have sufficient tire clearance to the floor. Under certain loading and road conditions during travel, the tire may come in contact with the underside of the floor causing damage to the floor covering. Over time this condition can lead to a tire failure resulting in an increased risk of property damage and poor vehicle handling.

Models Included:	2018 – 2019 Kodiak Travel Trailers: Models 255BHSL, 283BHSL
Serial Number Ranges:	2018 JJ971503 – JJ973935
	2019 KJ970266 – KJ971851
Parts Required:	6 – KRV # 238533 – Axle – AP Kit – 7/16-20 – Flange Nut (This part may be ordered in bulk without a VIN) No Canadian Sales
	2 – KRV # 505103 – Axle – Equalizer Only – EQ310 – w/Nylon Bushings (This part may be ordered in bulk without a VIN)
Tools Required:	– 11/16” Deep Well Socket – ¾” Deep Well Socket – Ratcheting Wrench

 

Note – Check serial number on Key Express to verify the campaign is open. Some vehicles were repaired before they left Keystone.

When performing warranty or recall service, please make certain that appropriate Personal Protective Equipment (PPE) is used.

The remedy is to increase clearance between the tire and the floor by replacing the existing center equalizer with a taller equalizer, KRV # 505103 – Axle – Equalizer Only – EQ310 – w/Nylon Bushings. The flange nuts cannot be re-used.

 

REPAIR INSTRUCTIONS

ONE: PREPARE THE UNIT

Step 1 Park the trailer on a level surface area.

Step 2 Disconnect all internal and external power supplies.

Step 3 Locate the equalizers (Figure 1A) and clean all debris from them.

 

TWO: REMOVE THE EQUALIZER

NOTE: Do not lift the trailer by the axles. The axles were not designed as a viable lift point.

Step 1 Using the properly-rated floor jack, lift the trailer in front of and behind the axles at the frame until the wheels are no longer in contact with the ground.

Step 2 Support framework using jack stands.

Step 3 Remove the wheels and set aside wheels and lug nuts.

Step 4 Using a floor jack, lift the axles slightly and place the additional properly-rated jack stands under the axles (Figure 2) so that the shackle bolts can be driven out with a hammer.

Step 5 With an impact gun or an appropriate wrench, loosen both the nut on the equalizer bolt and the nuts on the shackle bolts (Figure 3).

NOTE:Hold the head of the bolts with a wrench.

Step 6 Drive out the equalizer bolt with a hammer, so the equalizer bolt unseats from the hanger.

NOTE: A pry bar may be used to remove the equalizer bolt.

NOTE: The equalizer should hang freely from the shackle links.

Step 7 The shackle link assembly with the shackle bolts (Figure 3) should be removed from the leaf spring eyelets.

Step 8 The trailer is ready for the installation of the new equalizer 1 – KRV # 505103 – Axle – Equalizer Only – EQ310 – w/Nylon Bushings (This part may be ordered in bulk without a VIN).

 

THREE: INSTALL THE NEW EQUALIZER

Step 1 Install the new equalizer (KRV # 505103 – Axle – Equalizer Only – EQ310 – w/Nylon Bushings) into the hanger.

Step 2 Install the equalizer bolt (Figure 4) through the first bracket of the hanger, then through the topmost Nylon bushing of the equalizer and, finally, through the second bracket of the hanger.

Step 3 Use a hammer and drive the equalizer bolt into the hanger. This will seat the serrations of the bolt against the hanger surface and provide resistance to rotation when tightening.

NOTE: The equalizer bolt must be installed from the outside in toward the center of the trailer chassis. This ensures the bolt threads do not interfere with any other assemblies.

Step 4 Install the nut onto the equalizer bolt until the nut seats against the shoulder bolt. Torque nut to 30-50 ft-lbs.

NOTE:When installing the nuts, be sure to use a wrench to hold the bolt heads.Step 5Utilizing the floor jacks, lift the axles into the normal operating positions.

Step 6 Using shackle bolts and nuts, attach the shackle links (Figure 4) to the equalizer pivot arm bushings and the leaf springs.

Step 7 Tighten all nuts until they bottom out on the shoulder bolts at 30-50 ft-lbs.

Step 8 Repeat Steps 1 through 8 under the Removal section for the opposite side of the trailer.

Step 9 Repeat Steps 1 through 7 under the Installation section for the opposite side of the trailer.

NOTE: Check bolts at hangers (Figure 5) for wear and damage and replace as needed.

Step 10 Install wheels and apply lug nuts using the following process:

 

FOUR: WHEEL INSTALLATION 

WHEEL & HUB PAINT MUST BE REMOVED PRIOR TO WHEEL REINSTALLATION

Step 1 The black paint that has transferred from the hub face to the mounting surface of the wheel must be fully removed.

Step 2 For the wheel, apply lacquer thinner to the back side (hub-mating surface) side of the wheel with a shop rag to soften the black paint. Rub the area with a type “A” very fine Scotch-Brite® pad until clean. Dry the surface completely. See Figures 5 & 6.

Warning: Do not allow solvent or equivalent to make contact with the tire. Do not use liquid paint remover as this will pit and damage the aluminum wheel. Do not use a wire wheel (brush) or grinder to remove the paint from the wheel as this will also damage the wheel.

 
Step 3 For the hub face, apply liquid paint remover or equivalent to the wheel-mating surface of the hub. Use a wire wheel (brush) to clean all black paint from the wheel-mating surface, that is, all areas of the hub face that come in direct contact with the wheel. Avoid damaging the hub face with this process! After the paint is removed, wash off the area with water to remove any remaining residue. Dry the surface completely. See Figures 7 & 8.

Step 4 Make a final inspection of these surfaces before mounting the wheels. If any grease is present use a brake cleaner or degreaser. Rinse any cleaned areas with water to remove residue. Dry the surface completely. See Figure 8.

Warning: When using chemicals (paint remover, brake cleaner/degreaser) be sure to utilize the “Personal Protective Equipment” (PPE) recommended by the manufacturer through the Safety Data Sheet (SDS) and dispose in accordance with all Federal, State and Local Laws.

Warning:  When cleaning the hub face with the wire wheel brush avoid excessive pressure on the studs. Applying too much force here could damage the threads on the studs.

 

FIVE: WHEEL ASSEMBLY INSTALLATION

Step 1 Using a clean rag, wipe down all lug nuts and tapered nut seats on wheel to remove any foreign debris.

Step 2 Start the lug nuts on each stud by hand.

Step 3 You must use the star pattern and torque wrench when tightening the lug nuts to the wheel. This sequencing pattern shows how to progressively tighten the lug nuts to best achieve the proper torques and clamp load. See Figure 9.

Step 4 Using the star pattern outlined in Figure 9, tighten the lug nuts until the 1^st stage torque (2025 ft-lbs ) outlined in Figure 10 is achieved. Verify the lug nuts are properly positioned in the tapered seats of the wheel.

	Wheel Torque Requirements
Wheel Size	1st Stage	2nd Stage	3rd Stage
15″	20-25 ft-lbs	55-60 ft-lbs	110-120 ft-lbs

 

Step 5 Using the star pattern outlined in Figure 9, tighten the lug nuts until the 2^nd stage torque (5560 ft-lbs) outlined in Figure 10 is achieved.

Step 6 Lower the trailer to the ground.

Step 7 Using the star pattern outlined in Figure 9, tighten the lug nuts until the 3^rd and final stage (110-120 ft-lbs) is achieved. See Figure 10.

Step 8 Use a dial or digital torque wrench to verify that the proper amount of torque has been applied.

NOTE: Reminder – Follow-Up re-torque required at 10, 25, and 50 miles.

Step 9 Remove the jack stands and lower the trailer evenly to the ground. Make sure the shackle links are upright and located approximately in the 10 o’clock and 2 o’clock positions.

NOTE: To ensure that the shackle links do not flip either up or down, lowering of the trailer must be with even distribution and without jarring movement. The trailer MUST not be dropped to the ground.

Proceed to warranty reimbursement.

             

WARRANTY REIMBURSEMENTREPAIR

Submit the claim on Key Express using Flat Rate Code # 7134942B

In the Complaint section note: Safety Advisory # 19-349

In the Cause section note: Safety Advisory # 19-349

In the Correction section note: Replaced equalizer and flange nuts

The amount of time authorized for this repair is 2.0 hours.

 

PARTS DISPOSITION

No part return.

Please call Keystone RV Customer Service at 855-382-4100 if you have any questions.

 

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RECREATIONAL VEHICLE
SAFETY RECALL NOTICE

Safety Recall: 19V-231
Safety Advisory: 19-349
April 16, 2019

 

IMPORTANT SAFETY RECALL

«Owner_name»
«Street»
«Street_2»
«City», «State»  «Zip»

 

This notice applies to your vehicle:  «VIN» Dear «Owner_name»:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model 2018-2019 Dutchmen Kodiak Travel Trailers. As a result, Keystone RV is conducting a safety recall. We apologize for any inconvenience this action may cause you; however your safety and continued satisfaction are of the utmost importance to us.

Reason for this recall	It has been decided that the vehicles in the recall population may not have sufficient tire clearance to the floor. Under certain loading and road conditions during travel, the tire may come in contact with the underside of the floor causing damage to the floor covering. Over time this condition can lead to a tire failure which can cause property damage and poor vehicle handling increasing the risk of a crash.
What we will do	Keystone representatives have been in contact with the staff at your selling dealership regarding this situation. The remedy is to install a suspension lift kit to the unit. The service and parts required for this corrective action will be provided at no charge to you.
What we need you to do	As soon as possible, please make an appointment to have your RV serviced by your dealership. The labor time to perform this correction is approximately 2 hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your RV for this repair.
If you have questions	Your dealer is best equipped to obtain parts and provide service to ensure your RV is corrected as promptly as possible. Please contact Keystone Customer service if your dealer is unable to assist or if you take your RV to your dealer on the agreed service date, and the dealer does not remedy the condition within a reasonable amount of time, or without charge to you. You may be eligible to receive reimbursement if you paid to have the defect resolved prior to receiving this correspondence. Keystone Customer Service is available toll-free at 1-866-425-4369.

 

If after contacting Keystone Customer Service you are still not satisfied we have done our best to remedy this situation, you may also submit a written complaint to: Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590. You may call the toll-free Vehicle Safety Hotline at 1-888-3274236 (TTY:  1-800-424-9153; or go to https://www.safercar.gov.) Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Thank you for your attention and cooperation in this matter.

Sincerely,

KEYSTONE RV COMPANY

Rick Deisler
Vice President Service Operations
cc:  National Highway Traffic Safety Administration (NHTSA)

PO Box 2000 – Goshen, IN  46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com

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RECREATIONAL VEHICLE
SAFETY RECALL NOTICE
Safety Recall:
US: 19V-231
CAN: 2019-157
Safety Advisory: 19-349
April 11, 2019

 

SAFETY ADVISORY 19-349

«Dealer_name»
ATTN: Service Manager
«Street»
«Street_2»
«City», «State»  «Zip»
«Country»

 

Dear «Dealer_name»,

Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model 2018-2019 Dutchmen Kodiak Travel Trailers. As a result, Keystone RV is conducting a safety recall.

Reason for      _{to the floor. Under certain loading and road conditions during travel, the tire may come in contact} It has been decided that the vehicles in the recall population may not have sufficient tire clearance this recall           with the underside of the floor causing damage to the floor covering. Over time this condition can lead to a tire failure resulting in an increased risk of property damage and poor vehicle handling. The vehicles included in the recall are:

2018-2019 Kodiak, Models:
255BHSL, 283BHSL

Serial Number Range:
2018  JJ971503 – JJ973935
2019  KJ970266 – KJ971851

Our records indicate unit(s) sold or in your present lot inventory fall within this range, which will require immediate preventative action. Important: If some of the units are still in your inventory, Federal Law requires you to complete the recall service on those units before retail delivery. The unit VIN(s) our records indicate are presently in your inventory or have been sold are as follows:

«VIN1»

—  Serial numbers with ‘*’ have been retail sold  —

Claims for the units which have been serviced must be submitted. Claims submitted will be used by Keystone to record recall service completions and provide dealer payments. Enclosed is a copy of the Safety Advisory #19-349, which details how to remedy the situation and the proper reimbursement procedures.

We apologize for any inconvenience this situation may cause and greatly appreciate your cooperation. Should you have any questions or concerns regarding this correspondence or the enclosed Safety Advisory, please feel free to contact us.

Sincerely,

KEYSTONE RV COMPANY

Rick Deisler

Vice President Service Operations

cc. National Highway Traffic Safety Administration (NHTSA)
cc. Transport Canada

PO Box 2000 – Goshen, IN  46527-2000
Phone: (574) 535-2100 – Fax: (574) 535-2199
www.keystonerv.com

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2 Affected Products

Vehicle

DUTCHMEN

KODIAK

2018-2019

 

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12 Associated Documents

Remedy Instructions and TSB

RCRIT-19V231-5318.pdf 223.863KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V231-0084.pdf 89.687KB

 

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Miscellaneous Document-Recall 19-349 Kodiak Tire Clearance Dealer EMAIL

RMISC-19V231-1742.pdf 133.83KB

 

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Miscellaneous Document-19-349 recall tweet screenshot

RMISC-19V231-9843.pdf 52.423KB

 

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Miscellaneous Document-19-349 Kodiak Tire Clearance – Web

RMISC-19V231-1272.pdf 63.571KB

 

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Defect Notice 573 Report

RCLRPT-19V231-7646.PDF 214.421KB

 

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Recall Acknowledgement

RCAK-19V231-6178.pdf 245.611KB

 

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Manufacturer Notices(to Dealers,etc)-19-349 Kodiak Tire Clearance Recall Dealer Letter

RCMN-19V231-8043.pdf 92.136KB

 

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Recall Quarterly Report #1, 2019-2

RCLQRT-19V231-8677.PDF 211.132KB

 

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Recall Quarterly Report #3, 2019-4

RCLQRT-19V231-9985.PDF 211.319KB

 

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Recall Quarterly Report #2, 2019-3

RCLQRT-19V231-0518.PDF 211.231KB

 

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Miscellaneous Document – Manufacturer Notices(to Dealers,etc)

RMISC-19V231-0880.pdf 126.725KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V231&docType=RCL

 

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