9901519 – Leveling System Mounting Bracket May Fail – 2016-2019 Jayco & Entegra Motorhomes

September 9, 2020 NHTSA CAMPAIGN NUMBER: 20V548000

Leveling System Mounting Bracket May Fail

Contact with the ground may cause the pump and reservoir to detach or leak hydraulic fluids, increasing the risk of a crash.

 

NHTSA Campaign Number: 20V548

Manufacturer Jayco, Inc.

Components EQUIPMENT

Potential Number of Units Affected 4,036

 

Summary

Jayco, Inc. (Jayco) is recalling certain 2016-2018 Jayco Seneca, 2016-2019 Jayco Greyhawk, 2016 and 2018-2019 Jayco Redhawk, 2017 Jayco Envoy 200 Series and 2018-2019 Entegra Odyssey, Jayco Esteem, and Jayco Greyhawk Prestige motorhomes. The mounting brackets for the leveling system hydraulic pump and reservoir may fail allowing the components to contact the ground.

 

Remedy

Jayco will notify owners and dealers will install an additional support bracket, free of charge. The recall began November 6, 2020. Owners may contact Jayco’s customer service at 1-800-517-9137. Jayco’s number for this recall is 9901519.

 

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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Hydraulic Leveling System – Pump & Reservoir Support Bracket

Bulletin Type:	Safety Recall		Publication Date:	November 6, 2020
Bulletin #(s):	20V-548 US Units 2020-426 CN Units		Make(s):	Jayco Motorized Entegra
			Model(s):	Seneca, Greyhawk, Greyhawk Prestige, Redhawk, Odyssey, Esteem, Envoy 200 Series
Job Code:	9903519
Flat Rate:	2 Hours
			Model Year(s):	2016-2019

 

Incident:	The supporting bracket for the hydraulic pump and reservoir breaks, allowing the pump and reservoir to fall to the ground.
Affected Units:	All units with a hydraulic system installed by Jayco during the original build.  CASE RECALL LINES in Jayco Partners note the affected unit serial numbers.
Parts Kit:	Parts Kit #:  20V-548 – Available to ship- week of 11-23-2020
	Parts Kit Contents: (4) .38-16 zinc hex nut (4) .38-16×1.00 GR5 zinc carriage bolt (4) .38 zinc USS flat washer (4) .38 zinc split lock washer (2) .38-16×1-1-1/2 grade 5 zinc hex tap bolt (1) .13 steel black 13.50×11.69×2.13 bracket
Misc. Tools & Supplies:	Sawzall with steel cutting blade OR 4” die grinder 9/16”  long socket and ratchet 9/16” open end wrench Box to support the pump during the repair 9/16” short socket and extender
Parts Return Information:	No parts are to be returned

 

INSPECTION

Inspect hoses and connection for damage, sign of wear or loose connections.

 

INSTRUCTIONS

NOTE:  The repair will be easier if you do not set the emergency brake on the motorhome. This will allow more slack in the brake cable in the bracket area. Be sure to block the tires and put the gearshift in park to prevent the motorhome from moving during the repair.

 

1. Obtain a box or similar support mechanism to support the leveling pump so when you remove the bolts from the support bracket you can lower the pump on it. Make sure the support is high enough as to not stress any hydraulic connections once the pump is resting on it. (Picture #2)

 

2. Using a 9/16” sock wrench, loosen and remove the (2) bolts securing the pump to the support bracket. Remove the bolts and discard, set aside the nuts and lock washers for attaching the new bracket. (Picture #1).

 

3. Lower the hydraulic pump onto the support box. Insure Make sure the support is high enough as to not stress any hydraulic connections once the pump is resting on it. (Picture #2)

 

4. Using a sawzall or 4” die grinder, cut the existing support bracket off even with the bottom of the frame rails (Picture 3 & 4). Use caution to insure sparks do not damage the hydraulic hoses and reservoir container.

 

5. Install Part A of the bracket on the frame rail. It should be placed over the remaining part of the original bracket and on the inside of the emergency brake cable. The top will “hook” over the rail (towards the hydraulic pump).

Install Part B of the bracket with the support portion towards the hydraulic pump.  Join the (2) bracket pieces together by inserting the (4) carriage bolts through the holes on the top of Part A and on through the holes on Part B.  Add the flat washer, the split washer and the nut on each bolt.  Using the long socket and ratchet, firmly tighten each nut.

 

6. Set the hydraulic pump onto the top surface of the new bracket. (Picture #6) Insert the (2) new Hex Bolts through the top of the pump bracket (where the original bolts were).  Set the hydraulic pump on the bracket, making sure the bolts are through the holes on the bracket plate C shown on Diagram #5.  Adjust the hydraulic pump position as needed to insure it is securely seated on the bracket.

 

7. Install the original lock washer and nut onto the pump bolt securing the pump to the bracket. Access to the bolt is through the (2) holes in the bottom of the bracket. (Picture #7)

 

NOTE:  To make the nut/washer installation easier, place an extra nut into a short 9/16” socket with an extender on it.  Place the nut with the lock washer on top, into the socket.  Insert the washer/nut into the hole to get it started.

 

8. Using the long socket and ratchet, tighten the nuts through the holes in the bottom of the bracket. You may need to use the 9/16” open wrench to hold the bolt head while tightening the nut. Securely tighten nuts on both bolts. (Picture 8 & 9)

 

Jayco’s sole obligation under our limited warranty is to repair or replace defective materials and/or workmanship deemed our responsibility as determined by Jayco in our sole discretion. Jayco reserves the right to use new and/or remanufactured parts or materials of similar quality to complete any work, and to make parts and/or design changes as appropriate without notice to anyone. Jayco designs and/or materials changes are done without obligation to incorporate such changes in previously manufactured product. Jayco makes every reasonable effort to ensure field remedies will not adversely affect performance and/or safety of the unit. This field remedy is not intended to extend to future performance of this RV, or any of its materials, components or parts beyond the standard warranty period. The RV owner’s obligation to notify Jayco, or one of its independent, authorized dealers, of a claimed defect does not modify any obligation placed on the RV owner to contact Jayco directly when attempting to pursue remedies under state or federal law.  Jan. 2019.

903 South Main Street  •  P.O. Box 460  •  Middlebury, IN 46540

 

20V-548 2020-426 Support Bracket

November 2020

 

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Safety Recall:  20V-548  2020-426

November 6, 2020

 

IMPORTANT SAFETY RECALL 

 

This Notice Applies to Your Recreational Vehicle   «unit_serial_»

 

Dear Valued Customer:

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

 

Jayco has decided that a defect, which relates to motor vehicle safety, exits in certain 2016-2019 Seneca, Greyhawk, Greyhawk Prestige, Redhawk, Odyssey, Esteem and Envoy 200 series motorhomes manufactured with a hydraulic leveling system.

 

Reason for this recall

The supporting structure for the hydraulic leveling system pump and reservoir may fail. Failure could potentially allow the pump and reservoir to contact the ground, which may result in either a complete separation and/or the possibility of hydraulic fluid loss, increasing the risk of a crash and/or property damage.

 

Recall Remedy

The supporting structure for the leveling system’s hydraulic pump and reservoir requires additional support to prevent failure. The remedy is free of charge and will take approximately 2 hours to complete.

 

What we need you to do

Please contact your Dealer and set an appointment for this remedy.

 

If you had this repair completed prior to receipt of this recall notice, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall.

 

If you take your recreational vehicle to your dealer on the agreed service date and the dealer does not remedy this condition on that date or within three (3) days, please contact our Customer Service Department at 800-517-9137. If you are unable to get this safety defect remedied without charge and/or within a reasonable amount of time after contacting your dealer and Jayco customer service, you may want to contact NHTSA. To submit a written complaint, contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153): or go to https://www.safercar.gov.  

 

We certainly regret this inconvenience; however, your safety is our most important priority.

 

Sincerely,

Compliance Management

Jayco Motorized

 

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573 – CHRONOLOGY OF DEFECT

 

7-9-20 NHTSA and Jayco met via turbo meeting to discuss previous TSBs ( 17-011 and 19-022) and additional units reporting the pump and reservoir came in contact with the ground.  Based on the current facts, an increase of concern for the consumer’s safety, warranted elevation of the TSBs to a Recall status.   Recall 20V-405 – filed to address poor welds on units affected by previous TSBs.  During the research to capture all potentially defective units in the scope of the new recall, (20V-405) numerous 2019 motorhomes noted the same poor weld failure.  These units have the new design and manufactured after the change supplier made in August 2019.

 

7-13-20 – Incident reviewed at WIRC 2019 Greyhawk – hydraulic pump dragging on ground – per consumer – welding of the pump support was inadequate.

 

7-15-20 Incident elevated to CPAC – 13 failures found on 2019 units produced after the supplier change to continuous weld ( 4-8-2019)  – Zero failures found on units built after 4-8-2019

 

7-2020 – 8-2020  Further research conducted to find ALL motorhomes produced with Hydraulic leveling system and complete assessment of ALL possible failure modes. – This research confirmed that 20162019 units defines the scope of the new recall.

 

9-3-20 SSC reviewed all details and approved filing of new recall for ALL units manufactured prior to 4-82019 with a hydraulic leveling system AND not listed under TSB 17-011 or 19-022 or Recall 20V-405.

PLEASE NOTE:   The August SSC meeting scheduled for 8-27-2020 was delayed one week.

 

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17 Affected Products

Vehicles

MAKE	MODEL	YEAR
ENTEGRA	ODYSSEY	2018-2019
JAYCO	ENVOY 200	2017
JAYCO	ESTEEM	2018-2019
JAYCO	GREYHAWK	2016-2019
JAYCO	GREYHAWK PRESTIGE	2018-2019
JAYCO	REDHAWK	2016, 2018-2019
JAYCO	SENECA	2016-2018

 

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13 Associated Documents

Chronology

RMISC-20V548-3714.pdf 72.64KB

 

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V548-0162.PDF 211.235KB

 

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Recall Acknowledgement

RCAK-20V548-4955.pdf 244.998KB

 

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Defect Notice 573 Report

RCLRPT-20V548-8476.PDF 212.672KB

 

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Defect Notice 573 Report

RCLRPT-20V548-5139.PDF 212.661KB

 

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Recall 573 Report – Amendment 1

RCLRPT-20V548-1187.PDF 212.672KB

 

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V548-5013.PDF 211.135KB

 

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Recall 573 Report – Amendment 2

RCLRPT-20V548-5213.PDF 213.136KB

 

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Remedy Instructions and TSB

RCRIT-20V548-9621.pdf 1188.694KB

 

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Recall Quarterly Report #3, 2021-2

RCLQRT-20V548-6858.PDF 211.321KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V548-3902.pdf 162.473KB

 

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V548-1931.PDF 211.236KB

 

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Recall Quarterly Report #4, 2021-3

RCLQRT-20V548-0836.PDF 211.422KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V548&docType=RCL

 

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