21-411 – Frame Rail May Buckle – 2017-2021 Keystone Cougar 368MBI Trailers

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May 24, 2021 NHTSA CAMPAIGN NUMBER: 21V380000

Frame Rail May Buckle

A buckled frame rail can increase the risk of a crash.

 

NHTSA Campaign Number: 21V380

Manufacturer Keystone RV Company

Components SUSPENSION, STRUCTURE

Potential Number of Units Affected 1,990

 

Summary

Keystone RV Company (Keystone) is recalling certain 2017-2021 Keystone Cougar 368MBI trailers. The frame rails do not have enough cross support, which could cause them to buckle under certain side-load stress conditions.

 

Remedy

Dealers will add cross braces between each spring hanger and an outrigger between the tires on the off-door side of the vehicle, free of charge. Owner notification letters were mailed July 15, 2021. Owners may contact Keystone customer service at 1-866-425-4369. Keystone’s number for this recall is 21-411.

 

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.nhtsa.gov.

 


Keystone RV Company

7/13/21

 

SAFETY ADVISORY # 21-411

Cougar 368MBI Frame Brace

Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided under certain side load stress conditions the frame exhibits excessive flexing at the area of the axle spring hangers. Under certain conditions during travel, the frame rail may yield and buckle possibly leading to an increased failure and vehicle crash.

 

Model: Cougar Fifth Wheel 368MBI

Year Serial Number Ranges
2017 H2507991 – H2507991
2018 J2500656 – J2513103
2019 K2500281 – K2512038

KR505946 – KR506005

2020 L2500107 – L2508889
2021 M2500058 – M2504615

 

Parts Required:

3 – KRV # 681711 – Frame – KS – Axle Brace Assembly – (Includes 1 hanger brace and 2 hanger plates) (This part may be ordered in bulk without a VIN)

1 – KRV # 501127 – Frame – Outrigger – Bolt On – 13.50″ x 6.88″ x 1.5″ (This part may be ordered in bulk without a VIN)

12 – KRV # 682401 – Bolt – #13 – 1/2″ x 1 1/2″ – Hex Cap – Zinc – GR5 (This part may be ordered in bulk without a VIN)

12 – KRV # 163795 – Nut – 13 – 1/2″ – Locknut – Hex – Nylon – Zinc (This part may be ordered in bulk without a VIN)

 

Tools Required:

– ¾” wrench – ¾” Socket and ratchet

– 3/8” nut driver

-screw gun

 

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 add cross braces across each set of spring hangers, three total, and add an outrigger directly above center spring hanger on the off door side of the unit.

 

REPAIR INSTRUCTIONS

Step 1

Locate the trailer on a level, flat, hard surface. Chock the wheels.

 

Step 2

Locate the front, middle, and rear sets of spring hangers on the frame.

 

Step 3

Add KRV# 681711 Frame – KS – Axle Brace Assembly – (Includes 1 hanger brace and 2 hanger plates)  as shown in Figures 1 and 2 using KRV# 682401 Bolt – #13 – 1/2″ x 1 1/2″ – Hex Cap – Zinc – GR5 and KRV# 163795 Nut – 13 – 1/2″ – Locknut – Hex – Nylon – Zinc to attach the brace to each set of spring hangers.

 


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 2017-2021 Cougar Fifth Wheels. 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 under certain side load stress conditions the frame exhibits excessive flexing at the area of the axle spring hangers. Under certain conditions during travel, the frame rail may yield and buckle possibly leading to an increased failure and vehicle 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 add cross braces between each spring hanger and an outrigger between the tires on the off door side of the vehicle. The service and parts required for this corrective action will be provided at no charge to you.

 

What we need you to do

Unload the vehicle before transporting to the dealer for repairs. 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 1 hour. 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

 



5 Affected Products

Vehicle

MAKE MODEL YEAR
KEYSTONE COUGAR 2017-2021

 


9 Associated Documents

Remedy Instructions and TSB

RCRIT-21V380-1169.pdf 164.259KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V380-0952.pdf 92.648KB

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Manufacturer Notices(to Dealers,etc)

RCMN-21V380-8055.pdf 97.495KB

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Manufacturer Notices(to Dealers,etc)-Dealer Email

RCMN-21V380-0523.pdf 89.931KB

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Recall 573 Report – Amendment 1

RCLRPT-21V380-9113.PDF 215.662KB

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Recall Acknowledgement

RCAK-21V380-4359.pdf 646.246KB

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Defect Notice 573 Report

RCLRPT-21V380-6968.PDF 215.622KB

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Recall Quarterly Report #2, 2021-4

RCLQRT-21V380-6568.PDF 211.23KB

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Recall Quarterly Report #1, 2021-3

RCLQRT-21V380-6852.PDF 211.124KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V380&docType=RCL

 


 

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