March 19, 2018 NHTSA CAMPAIGN NUMBER: 18V180000
If the spare tire detaches from the vehicle, it may become a road hazard, increasing the risk of a crash.
NHTSA Campaign Number: 18V180
Manufacturer Forest River
, Inc.
Components TIRES
Potential Number of Units Affected 71
Summary
Forest River, Inc. (Forest River) is recalling certain 2018 No Boundaries recreational trailers, models NBT10.5 and NBT10.6. The spare tire mount may not be strong enough and the spare tire may detach from the trailer.
Remedy
Forest River will notify owners, and dealers will replace the spare tire mount, free of charge. The recall began on April 25, 2018. Owners may contact Forest River customer service at 1-574-642-1612. Forest River’s number for this recall is 77-0662.
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.
FOREST RIVER SPARE TIRE CARRIER REPAIR RECALL #18V-180
Purpose
This document refers to the repair of Forest River No Boundaries 10 Series travel trailers. Forest River has announced a recall on the spare tire carrier for the No Boundaries 10 Series travel trailer models. The spare tire carrier, which is mounted on the side, is cracking the main rail. To remedy the problem, LCI has created a repair procedure which includes a new subassembly with a receiver tube to be bolted to the main rail.
Safety
Unprotected flammable underbelly features may cause a fire or explosion that could result in death, serious personal injury or severe product or property damage. Isolate or shield flammable underbelly features from excessive heat and sparks generated during welding operation.
Make sure the trailer is properly supported before performing any maintenance or repair work. Follow the trailer manufacturer’s recommendations for supporting the trailer. Use proper personal protective equipment.
Welding generates excessive heat, hot sparks and blinding light, which can cause serious personal injury. Use appropriate personal protective equipment for welding, cutting and grinding.
Resources Required
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Repair Parts
| Part # | Description of kits | Qty |
|---|---|---|
| 728581 | Bolt-on No Boundaries spare tire repair subassembly kit; includes hardware listed below | 1 |
| 721401 | Spare tire carrier, new (ordered separately) | 1 |
| Part # | Description of parts contained in subassembly kit | Qty |
| 728579 | Bolt-on spare tire repair subassembly | 1 |
| 118230 | 1/4″ – 14 x 3/4″ screw, self-drilling hex washer-head | 4 |
| 132696 | 1/2″ – 13 x 3 1/4″ bolt, yellow Zinc, Grade 5 | 4 |
| 135855 | 1/2″ flat washer, Zinc | 8 |
| 118045 | 1/2″ – 13 nylon locking nut, Zinc | 4 |
| 383495 | 3/8″ – 16 x 3 1/2″ bolt, Grade 8; or a Grade 5 minimum equivalent | 2 |
| 119075 | 3/8″ flat washer , Zinc | 4 |
| 118044 | 3/8″ – 16 nylon locking nut, Zinc | 2 |
Preparation
Note: Orange lines indicate where material will be removed by cutting.
- Support the trailer in accordance with the manufacturer’s recommendations.
- Remove old spare tire carrier.
- Make sure the area is clear of insulation, obstructions and fire hazards.
- Cut away both spare tire carrier tubes from the main rail (Fig. 1).
- Inspect area for cracking and, if needed, repair cracks with welds.
- Grind down repair to provide a flat surface for attaching the repair subassembly (Fig. 2). Take care not to compromise the tube wall.
- After welds have cooled, clean and paint welded areas.
Procedure
- Place the repair subassembly (Fig. 2) under the main rail so the rail bisects the wider front plate and the narrower back plate of the subassembly (Fig. 4).
A. For proper horizontal placement, place the left edge of the front plate flush against the end of the main rail (Fig. 3).
B. For proper vertical placement, slide the subassembly upward until the receiver tube is held firmly against the bottom of the main rail (Fig. 4) and the bracket is flush with the top of the main rail.
Note: If subassembly is not flush with the top of the main rail, the rail will pucker when the fasteners are tightened.
- Using the pre-drilled holes in the four corners of the front plate, install four 1/4″ – 14 x 3/4″ self-drilling screws (Fig. 3).
- Locate the larger pre-drilled bolt holes in the subassembly above the receiver tube (Fig. 3).
- With a 1/2″ drill bit and using the subassembly’s pre-drilled holes as a template, drill four bolt holes through the main rail and rear plate.
- Place a 1/2″ flat washer onto a 1/2″ – 13 x 3/4″ Grade 8 bolt.
- Insert 1/2″ bolt with washer through one of the bolt holes (Fig. 5), then place a 1/2″ flat washer and a 1/2″ nylon locking nut onto the end of the bolt (Fig. 6).
- Repeat steps 5 and 6 for the other three bolts.
- Torque nuts to 30 ft-lbs to secure subassembly.
- Place new spare tire carrier on receiver tube (Fig. 7).
- Place 3/8″ flat washers onto 3/8″ – 16 x 3 1/2″ Grade 8 bolts, and then insert bolts through the two new spare tire carrier mounting bolt holes and the receiver tube mounting bolt holes.
- Place 3/8″ flat washers and 3/8″ locking nuts onto the ends of the bolts.
- Tighten nuts to safely secure new spare tire carrier to the receiver tube.
As a supplier of components to the RV industry, safety, education and customer satisfaction are our primary concerns. Should you have any questions, please do not hesitate to contact us at (574) 537-8900 or by email at [email protected]. Self-help tips, technical documents, product videos and a training class schedule are available at lci1.com or by downloading the MyLCI app.
NO BOUNDARIES SPARE TIRE CARRIER RECALL INSTRUCTIONS
1.) Reposition both front stabilizer jacks from the sidewall parallel position to the angle position as shown in photos. This will require a tack weld on both jacks both removal and install.
2.) The LP quick disconnect located on the door side of the A-frame will need to be repositioned 14” from the back of the A-frame. There are two self-tapping screws holding the disconnect onto the frame.
3.) The breakaway switch will also need to be repositioned if needed once stabilizer jack have been moved.
4.) Follow Lippert’s instructions.
5.) Once the new tire carrier has been installed you will need to run the wires through the opening of the new carrier as shown in photo to connect the clearance light on the carrier.
1 Affected Product
Vehicle
| FOREST RIVER | NO BOUNDARIES | 2018 |
7 Associated Documents
Recall Acknowledgement
RCAK-18V180-9589.pdf 247.432KB
Defect Notice 573 Report
RCLRPT-18V180-7246.pdf 215.466KB
Remedy Instructions and TSB
RCRIT-18V180-1873.pdf 4201.155KB
Remedy Instructions and TSB
RCRIT-18V180-8398.pdf 215.911KB
Recall Quarterly Report #4, 2019-1
RCLQRT-18V180-6709.PDF 211.41KB
Recall Quarterly Report #3, 2018-4
RCLQRT-18V180-6341.PDF 211.311KB
Recall Quarterly Report #2, 2018-3
RCLQRT-18V180-8958.PDF 214.597KB
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