RC000172 – Loose Battery Cables May Cause Fire – 2020 Thor Chateau, Daybreak, Four Winds, Freedom Elite, Majestic, Outlaw & Quantum Motorhomes

August 20, 2019 NHTSA CAMPAIGN NUMBER: 19V609000

Loose Battery Cables May Cause Fire

The loose connection can causing arcing, increasing the risk of a fire.

 

NHTSA Campaign Number: 19V609

Manufacturer Thor Motor Coach

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1,941

 

Summary

Thor Motor Coach (TMC) is recalling certain 2020 Chateau, Daybreak, Four Winds, Freedom Elite, Majestic, Outlaw and Quantum motorhomes. The battery cables may loosen on the battery isolation manager (BIM) or battery isolation relay (BIR), causing premature BIN/BIR failure or electrical arcing.

 

Remedy

TMC will notify owners, and dealers will install lock washers to properly secure the battery cable to the BIM/BIR. If the cable was loose, dealers will also replace the BIM/BIR, free of charge. The recall began October 10, 2019. Owners may contact TMC customer service at 1-877-855-2867. TMC’s number for this recall is RC000172.

 

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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Thor Motor Coach
Recall Repair Instructions

Recall #	19V-609 2019-426
Description/Title:	BIM/BIR WIRING
Affected Product Line(s):	Certain Model Year 2020 Chateau, Daybreak, Four Winds, Freedom Elite, Outlaw, Quantum, and Majestic Class C Ford motorhomes
Service Campaign # :	RC000172	Released Date:	09/30/2019
Repair Code:	TMCRC80486V	Document Date:	09/30/2019
Time Allowed:	0.75	Document Revision:	A

 

Issue: 

It has been discovered that on certain model year 2020 Chateau, Daybreak, Four Winds, Freedom Elite, Majestic, Outlaw, Quantum Motorhomes, a loose connection exists between the Battery Isolation Manager (BIM) or the Battery Isolation Relay (BIR) and attached battery cables. BIM/BIR are attached to battery cables and torqued per the specifications.  During mounting of the BIM/BIR in the motorhome and connection of the other end of the cables to the chassis battery, there is a possibility of the battery cable becoming loose on the BIM/BIR side depending on the orientation of the BIM when mounted and the ring connectors to bend. The loose connection not only causes premature failure of the BIM/BIR, but it can also create arcing, which can lead to a fire and property damage.

 

Parts Required:

TMC Recall Part #0454899

 

Shop Supplies: 

(3) ¼” self-tapping screw
(4) #8 self-tapping pan head screws
(1) ¼” star washer

 

Tools Required:

½” socket for torque wrench (for battery cables)
3/8” screw gun bit (for ¼” self-tapping screws)
5/16” socket (to remove overflow bottle)
Electrical Tape
Heat gun
Screw Gun
Square head screw gun bit (for #8 selftapping screws)
Torque Wrench
Wire cutters
Wire Crimpers

 

YouTube Video Instructions Found Here: https://youtu.be/P5JIXUf7H6g

 

Instructions:

 

1. Disconnect battery cable on the negative post of the house battery located in the step well.
2. Disconnect battery cable from negative post of the chassis battery located under the hood.

 

3. Remove the coolant overflow bottle – keep the screws – set the coolant overflow bottle out of the way.

Leave hoses connected.

 

4. Locate BIM/BIR mounted on driver’s side inside fender.
5. Remove the screws holding the BIM/BIR to the inside fender.

 

6. Remove ground wire

 

7. Open the loom for the dash switch, locate the white and white with black tracer. Cut both wires.

 

8. Open the loom for the ignition power, locate the yellow wire and cut.

 

9. Remove the chassis battery cable and the house battery cable from the BIM/BIR and remove BIM/BIR.

Note: The BIM/BIR needs to be returned to Thor Motor Coach for payment of the recall repairs.

10. Measure 5 ½“ up and 2 ½“ in from the fender well. This is the location to mount the Trombetta solenoid.
11. Start a ¼” self-tapping hex head screw at the 5 ½” and 2 ½” mark on the fender wall. Slide Trombetta solenoid bracket into place on the self-tapping hex head screw and secure.

 

12. Install a ¼” self-tapping hex head on the other side of the bracket of the Trombetta solenoid.
13. Install ground wire, black wire with ring terminal, above Trombetta solenoid on the inside of the fender by using a ¼” self-tapping hex head using a 3/8” bit.

NOTE: Must use a star washer between the ring terminal and fender.

14. Mount the Isolater Relay Delay (IRD) beside the Trombetta solenoid and along the seam of the fender with 2 – #8 self-tapping pan head screws.
15. Verify which cable is coming from the chassis battery by tracing is back to the chassis battery. Remove the washer and nut from the Trombetta solenoid and secure the chassis battery cable to the large terminal post of the Trombetta solenoid closest to the firewall with the washer and nut.

Note: If either battery cable ring terminal is bent – straighten before securing.

16. Secure the house battery cable to the other large terminal post (towards the front) of the Trombetta solenoid – this house battery is to be secured together with the white wire of the emergency start switch. Put the battery cable on the post first, then place the white wire on top and secure with washer and nut.
17. Tighten nuts on both battery cables using a torque wrench to 45” lbs.
18. Locate and cut yellow ignition power wire, strip back, and connect to yellow wire w/ yellow butt connector from the fuse holder. Crimp and heat shrink using a torch or electric heat gun. Using electrical tape, tape both ends of the yellow wires.

 

19. Locate cut white wire and white with black tracer from the emergency start switch and strip back both wires.

Connect white wires with white butt connector and white with black wires white with black butt connector.

Crimp both wires and heat shrink. Use electrical tape to tape both ends of the wires.

 

20. Mount both fuse holders to inside fender in a location where accessible with coolant overflow bottle in place.

Mount using #8 self-tapping pan head screws.

21. Set coolant overflow bottle back in place – do not secure until you test system to see if all is working properly.

 

22. Reconnect house battery cable in the step well.

 

23. Reconnect chassis battery cable under the hood.

 

24. Test the emergency start switch by pushing the switch and listen for an audible clicking noise. This indicates the connection is proper. If you do not hear the clicking noise, check fuse holder and wire connections (white & white with black wires).

 

25. Start the engine, after 15-20 seconds, you should hear an audible clicking noise. This indicates the connection is proper.  If you do not hear the clicking noise, check fuse holder and yellow wire connections.

  

 

Verify the 2 gauge cable that runs from the Trombetta is supported away from the engine exhaust manifold and the rest of the exhaust, covering the area under the hood to the rear of the cab. If the 2 gauge cable is not secured away from the exhaust manifold or the rest of the exhaust, secure as indicated in the following image.

 

Secure battery cables tight to the chassis frame.  Keep battery cable away from exhaust and manifold.

 

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RECREATIONAL VEHICLE
SAFETY RECALL NOTICE

Safety Recall: 19V-609
Safety Advisory: RC000172
October 2019

 

IMPORTANT SAFETY RECALL
This notice applies to your vehicle:  «VIN»

 

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

 

Dear «Owner_name»:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Thor Motor Coach (TMC) has decided that a defect which relates to motor vehicle safety exists in certain model year 2020 motorhomes. As a result, TMC 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 discovered that on certain model year 2020 Chateau, Daybreak, Four Winds, Freedom Elite, Majestic, Outlaw, Quantum Motorhomes, a loose connection exists between the Battery Isolation Manager (BIM) or the Battery Isolation Relay (BIR) and attached battery cables. The loose connection not only causes premature failure of the BIM/BIR, but it can also create arcing, which can lead to a fire and property damage
What we will do	TMC has contacted your selling dealer and has instructed them on how to replace the BIM/BIR. This will be done at no cost to you the owner.  The remedy should take approximately 45 minutes to perform.
What we need you to do	At your earliest convenience, please contact your dealer and schedule an appointment to have this remedy completed. To locate the nearest authorized TMC service center, please visit https://www.thormotorcoach.com/locate–a–service–center/.  If you have questions concerning this recall or if you need any assistance, please contact the TMC Warranty/Service Department by mail at TMC, P.O. Box 1486, Elkhart, IN 46515-1486, by phone at 877-855-2867, or email at Recalls@TMCRV.com.

 

If you had appropriate repairs completed prior to receipt of this recall notice, and if you incurred any direct cost in connection with obtaining such repair, you may be eligible to receive reimbursement from TMC by contacting the TMC Warranty/Service Department.

If after contacting TMC 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 1-888-327-4236 (TTY:  1-800424-9153; 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,

Thor Motor Coach

 

Celina Tyler
Consumer Affairs Manager
cc:  National Highway Traffic Safety Administration (NHTSA)

 

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IMPORTANT SAFETY RECALL
RC000172
This notice applies to vehicle:  «VIN»

 

«Dealer_name»
«Street»
«City», «State»  «Zip»

 

Dear Dealer:

This Safety Recall Notice is sent to you in accordance with the requirements of the United States National Traffic and Motor Vehicle Safety Act and The Canadian Motor Vehicle Safety Act and is important for your safety.  

Thor Motor Coach (TMC) decided that a defect which relates to motor vehicle safety exists in certain models of the below listed motorhomes.

It has been discovered that on certain model year 2020 Chateau, Daybreak, Four Winds, Freedom Elite, Majestic, Outlaw, Quantum Motorhomes, a loose connection exists between the Battery Isolation Manager (BIM) or the Battery Isolation Relay (BIR) and attached battery cables. The loose connection not only causes premature failure of the BIM/BIR, but it can also create arcing, which can lead to a fire and property damage

The required action is to replace the BIM/BIR with a Trombetta solenoid.

 

Dealers that have stock units impacted by this recall can access the full list of affected VINs sold to their dealership by accessing the “Service Campaign” portion of the TMC Advantage Web Portal.  If any unit on this list has been retail sold you are asked to notify the retail owner as soon as possible of this recall because their vehicle was not registered at the time the retail notice was mailed.  Please immediately register any retail sold units on this list.  As a reminder, you are required by law to complete this recall on any stock units in inventory prior to retail sale.  Any vehicle lessor receiving this notice must forward a copy to the lessee within 10 days.    

If you have questions concerning this recall, please contact the TMC Warranty/Service Department by mail at TMC, P.O. Box 1486, Elkhart, IN 46515-1486, or by phone at (877) 500-1020. 

We apologize for this inconvenience; however, we have taken this action in the interest of customer safety and continued satisfaction with our products.  

 

Sincerely,

Celina Tyler
Consumer Affairs Manager

 

Re:  NHTSA Recall No. 19V-609
Transport Canada No. 2019-426

 

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7 Affected Products

Vehicles

MAKE	MODEL	YEAR
THOR	CHATEAU	2020
THOR	DAYBREAK	2020
THOR	FOUR WINDS	2020
THOR	FREEDOM ELITE	2020
THOR	MAJESTIC	2020
THOR	OUTLAW	2020
THOR	QUANTUM	2020

 

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12 Associated Documents

Recall Quarterly Report #2, 2020-1

RCLQRT-19V609-5706.PDF 211.229KB

 

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Remedy Instructions and TSB

RCRIT-19V609-1172.pdf 1962.826KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-19V609-6357.pdf 139.604KB

 

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Recall 573 Report-Amendment 2

RCLRPT-19V609-7176.PDF 218.986KB

 

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Remedy Instructions and TSB

RCRIT-19V609-6767.pdf 1970.531KB

 

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Recall Acknowledgement

RCAK-19V609-9372.pdf 289.851KB

 

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Recall 573 Report – Amendment 1

RCLRPT-19V609-2683.PDF 219.066KB

 

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Defect Notice 573 Report

RCLRPT-19V609-6943.PDF 218.101KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V609-1520.pdf 36.871KB

 

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Manufacturer Notices(to Dealers,etc)-RC000172 TMCRV Dealer Letter

RCMN-19V609-3415.pdf 139.604KB

 

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Recall Quarterly Report #1, 2019-4

RCLQRT-19V609-6316.PDF 211.129KB

 

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Recall Quarterly Report #3, 2020-2

RCLQRT-19V609-1072.PDF 211.318KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V609&docType=RCL

 

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Last update on 2025-04-15 / Affiliate links / Images from Amazon Product Advertising API

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