RC000247 External Compartment Door May Separate – 2017 Thor Challenger, Miramar, & Outlaw Motorhomes

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October 29, 2021 NHTSA CAMPAIGN NUMBER: 21V845000

External Compartment Door May Separate

A door skin that separates during transit can become a road hazard, increasing the risk of a crash.

 

NHTSA Campaign Number: 21V845

Manufacturer Thor Motor CoacheBay

Components STRUCTURE

Potential Number of Units Affected 424

 

Summary

Thor Motor CoacheBay (TMC) is recalling certain 2017 ChallengereBay, Miramar, and Outlaw motorhomes. The external compartment outer door skin may separate from the motorhome during transit.

 

Remedy

Dealers will inspect the compartment door skin and replace the door as necessary, free of charge. Owner notification letters were mailed December 28, 2021. Owners may contact TMC customer service at 1-877-855-2867. TMC’s number for this recall is RC000247.

 

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.

 


 


Issue:

On certain model year 2017 ChallengereBay, Miramar, and Outlaw motorhomes, the exterior compartment door skin may be separating from the unit due to potential de bonding of glue. If the compartment door skin were to completely separate while the motorhome is in motion, this could lead to property damage and/or crash.

 

Parts Needed:

TMC Recall Kit # 0515323

 

Instructions:

The following procedure is the recommended process established by Mishawaka Sheet Metal on behalf of Patrick Industries in regards to the recall pertaining to baggage doors. After careful research and consideration, the established procedure was decided on based on safety, efficacy and cosmetic appeal.

 

Inspection:

Visually inspect all compartment doors for potential delamination of compartment door skin. If none is present, inspection is complete and repairs are not needed. If delamination is present on one or more doors, continue to repair instructions below.

 

Repair: Wedge, Adhesive, Clamp

In this process, when/if a space of delamination is discovered

1. If needed, remove door(s) experiencing delamination from motorhome.
(Only remove if delamination is in area of door that cannot be repaired while still on motorhome) 2. Apply wedges to the space to create a bigger gap.

3. Apply the (recommended) PARTITE 7315 White Methacrylate Structural Adhesive into the gap and remove the wedges.

4. With even pressure, clamp the affected area for the recommended 12 16 minutes to allow adequate fixture time.

5. Allow affected doors to sit for 24 hours in order to fully cure.

6. Reinstall the doors if they were removed in Step 1.

Note: The adhesive used is very quick setting. Please be cognizant of the time spent working with the product. Purge the mixing tip slightly before each use.

Any questions? Please call (877) 500 1020 or Recalls@tmcrv.com.

 


Component NameComponent DescriptionComponent Part #: 
DOOR, BAGGAGE, KIT, TDR0099, OUTLAW, 37MD/37RB2017 Exterior Doors – 37RB0269515
DOOR, BAGGAGE, KIT, TDR0118, CHALLENGEReBay, 37LX2017/2017.5 Exterior Doors – 37LX0276402
DOOR, BAGGAGE, KIT, TDR0126, CHALLENGEReBay, 37GT/37DT2017 Exterior Doors – 37GT0277685
DOOR, BAGGAGE, KIT, TDR0131, WHITE, MIRAMAR, 34.12017 Exterior Doors – 34.10278340
DOOR, BAGGAGE, KIT, TDR0131, CHAMPAGNE, MIRAMAR, 34.12017 Exterior Doors – 34.10278341
DOOR, BAGGAGE, KIT, TDR0133, CHALLENGEReBay, 37KT2017 Exterior Doors – 37KT0279255
DOOR, BAGGAGE, KIT, TDR0136, WHITE, MIRAMAR, 34.32017 Exterior Doors – 34.30279411
DOOR, BAGGAGE, KIT, TDR0136, CHAMPAGNE, MIRAMAR, 34.32017 Exterior Doors – 34.30279412
DOOR, BAGGAGE, KIT, TDR0156, CHAMPAGNE, MIRAMAR, 34.22017 Exterior Doors – 34.20292297
DOOR, BAGGAGE, KIT, TDR0156, WHITE, MIRAMAR, 34.22017 Exterior Doors – 34.20292298
DOOR, BAGGAGE, KIT, TDR0163, CHALLENGEReBay, 37TB2017/2017.5 Exterior Doors – 37TB0300336
DOOR, BAGGAGE, KIT, TDR0166, CHAMPAGNE, MIRAMAR, 33.52017 Exterior Doors – 33.50303241
DOOR, BAGGAGE, KIT, TDR0166, WHITE, MIRAMAR, 33.52017 Exterior Doors – 33.50303242
DOOR, BAGGAGE, KIT, TDR0170, OUTLAW, 38RE2017 Exterior Doors – 38RE0308055
DOOR, BAGGAGE, KIT, TDR0193, CHALLENGEReBay, 36TL2017 Exterior Doors – 36TL0327165
DOOR, BAGGAGE, KIT, TDR0203, WHITE, MIRAMAR, 34.42017 Exterior Doors – 34.40332545
DOOR, BAGGAGE, KIT, TDR0203, CHAMPAGNE, MIRAMAR, 34.42017 Exterior Doors – 34.40332546
DOOR, BAGGAGE, KIT, TDR0210, OUTLAW, 38RF2017 Exterior Doors – 38RF0335142
DOOR, BAGGAGE, KIT, TDR0215, CHAMPAGNE, MIRAMAR, 35.22017 Exterior Doors – 35.20338004
DOOR, BAGGAGE, KIT, TDR0215, WHITE, MIRAMAR, 35.22017 Exterior Doors – 35.20338005
DOOR, BAGGAGE, KIT, TDR0220, OUTLAW, 37BG2017 Exterior Doors – 37BG0344304
DOOR, BAGGAGE, KIT, TDR0227, CHALLENGEReBay, 37YT2017/2017.5 Exterior Doors – 37YT0357111
DOOR, BAGGAGE, KIT, TDR0240, CHALLENGEReBay, 36TL2017.5 Exterior Doors – 36TL0365599
DOOR, BAGGAGE, KIT, TDR0241, CHALLENGEReBay, 37KT2017.5 Exterior Doors – 37KT0365600
DOOR, BAGGAGE, KIT, TDR0242, CHALLENGEReBay, 37LX2017.5 Exterior Doors – 37LX0365601
DOOR, BAGGAGE, KIT, TDR0243, CHALLENGEReBay, 37TB2017.5 Exterior Doors – 37TB0365602
DOOR, BAGGAGE, KIT, TDR0244, CHALLENGEReBay, 37YT2017.5 Exterior Doors – 37YT0365603
DOOR, BAGGAGE, KIT, TDR0248, CHAMPAGNE, MIRAMAR, 35.22017.5 Exterior Doors – 35.20365608
DOOR, BAGGAGE, KIT, TDR0246, CHAMPAGNE, MIRAMAR, 34.22017.5 Exterior Doors – 34.20365612
DOOR, BAGGAGE, KIT, TDR0245, CHAMPAGNE, MIRAMAR, 34.12017.5 Exterior Doors – 34.10365614

 


Chronology :

May 2018 to June 2020 – TMC received three separate VOQs from NHTSA regarding customer concerns on compartment doors coming loose. A claims analysis was completed and a significant issue was not determined.

October 12, 2021 – TMC received a new VOQ regarding a compartment door skin that completely separated from a motorhome.

October 15, 2021 – A new claims analysis was conducted and determined that a higher incidence of claims has occurred on model 2017 units produced at Plant 850B from 1/15/2016 to 9/30/2016.

October 22, 2021 – TMC Safety Committee met to discuss analysis findings and determined a recall would be necessary to address potentially affected 2017 units.

 


3 Affected Products

Vehicles

MAKEMODELYEAR
THORCHALLENGEReBay2017
THORMIRAMAR2017
THOROUTLAW2017

 


12 Associated Documents

Recall 573 Report – Amendment 1

RCLRPT-21V845-8933.PDF 216.224KB

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Recall Acknowledgement

RCAK-21V845-3368.pdf 645.545KB

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Recall 573 Report

RCLRPT-21V845-9406.PDF 216.221KB

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Miscellaneous Document – Involved Component List

RMISC-21V845-3766.pdf 216.132KB

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Recall 573 Report – Amendment 2

RCLRPT-21V845-5383.PDF 216.228KB

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Remedy Instructions and TSB

RCRIT-21V845-4743.pdf 919.338KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V845-7032.pdf 37.272KB

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Manufacturer Notices(to Dealers,etc)

RCMN-21V845-7090.pdf 137.748KB

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Recall Quarterly Report #1, 2021-4

RCLQRT-21V845-0004.PDF 211.125KB

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Recall Quarterly Report #2, 2022-1

RCLQRT-21V845-4709.PDF 211.228KB

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Recall Quarterly Report #3, 2022-2

RCLQRT-21V845-6253.PDF 211.312KB

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Recall Quarterly Report #4, 2022-3

RCLQRT-21V845-5644.PDF 211.415KB

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