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March 31, 2022 NHTSA CAMPAIGN NUMBER: 22V209000
Tire May Contact the Outrigger Causing Tire Damage
Damaged tires can fail, causing a loss of vehicle control and increasing the risk of a crash.
NHTSA Campaign Number: 22V209
Manufacturer Keystone RV Company
Components STRUCTURE, TIRES
Potential Number of Units Affected 513
Summary
Keystone RV Company (Keystone
) is recalling certain 2019-2022 Cougar 29FKD travel trailers. Improper clearance may allow the tires to contact the outrigger, causing damage to the tires.
Remedy
Dealers will notch the existing outrigger and install an additional outrigger between the two tires to provide proper clearance, free of charge. Owner notification letters were mailed May 12, 2022. Owners may contact Keystone customer service at 1-866-425-4369. Keystone
’s number for this recall is 22-430.
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.
4/28/22
SAFETY ADVISORY # 22-430
Cougar 29FKD Outriggers
Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash.
Models Included:
Year | Model | Serial Number Range |
2019
2020 2021 2022 |
Cougar 29FKD | KV510568 – KV510568
LV501245 – LV509098 MV501156 – MV512901 NV500784 – NV505003 |
Parts Required:
2 – KRV # 501127- Frame – Outrigger – Bolt On – 13.50″ x 6.88″ x 1.5″ (This part may be ordered in bulk without a VIN)
Tools Required:
– Screw gun
– 3/8” nut driver – reciprocating saw or grinder with cut off wheel
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 inspect both front tires and check for damage. Cut out the outrigger at each front tire to allow for minimum of 3” of clearance, then add the bolt-on outrigger above the center spring hanger on each side of the unit.
REPAIR INSTRUCTIONS
Step 1
Unload the cargo area, empty the fresh and holding tanks. The trailer must be unloaded in order to get an accurate measurement between the tire and the outrigger.
Step 2
Locate the trailer on a level, flat, hard surface. Chock the wheels.
Step 4
In between the wheels and above the middle spring hanger on both sides of the frame, add KRV # 501127 – Frame – Outrigger – Bolt On – 13.50″ x 6.88″ x 1.5″ using (3) ¼” – 14 x 1” self-drilling hex screws into the frame rail and (1) 3/8” x 1 ½” lag bolt in the outer-most hole of the floor, see Figure 2.
Step 5
Proceed to warranty reimbursement.
Chronology :
3/14/2022 – A claim was received that a Cougar 29 FKD had a tire that was damaged due to hitting an outrigger. A claim review was initiated that yielded 2 similar claims that had been misdiagnosed as suspension issues. Investigation into scope and range opened.
3/29/2022 – Investigation concluded and scope and range completed.
4 Affected Products
Vehicle
MAKE | MODEL | YEAR |
KEYSTONE![]() |
COUGAR | 2019-2022 |
10 Associated Documents
Recall Acknowledgement
RCAK-22V209-5440.pdf 645.771KB
Defect Notice 573 Report
RCLRPT-22V209-2130.PDF 215.372KB
Manufacturer Notices(to Dealers,etc)
RCMN-22V209-7285.pdf 143.177KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V209-1836.pdf 144.423KB
Remedy Instructions and TSB
RCRIT-22V209-8056.pdf 496.146KB
Manufacturer Notices(to Dealers,etc)- 22-430 dealer email sent 5-12-2022
RCMN-22V209-2305.pdf 132.053KB
Recall Quarterly Report #1, 2022-2
RCLQRT-22V209-8559.PDF 211.143KB
ISSUED Renotification Notice
RCRN-22V209-8562.pdf 106.028KB
Recall Quarterly Report #2, 2022-3
RCLQRT-22V209-5192.PDF 211.242KB
Recall Quarterly Report #3, 2022-4
RCLQRT-22V209-7301.PDF 211.332KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V209&docType=RCL
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- Premium FREE COUNTRY Heavy Duty 10 ply rated, load Range E, 2400LBS capacity!
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- Trailer tire 225/75R15 ST 225/75R15 225 75R15, Max Capacity: 2830pounds; Maximum PSI: 80; Rim Diameter: 15"; Rim Width: 6" ;Load Range: E= 10 Ply Construction.
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- Premium rubber-compound materials, double steel belts and full nylon plies combine for superior function and long life
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SEOCONTENT-START
PO Box 2000 – Goshen, IN 46527-2000 Phone: (574) 535-2100 – Fax: (574) 535-2199 www.keystonerv.com IMPORTANT SAFETY RECALL – 2nd Notice «POLKNAME» «POLKADDRESS» «POLKCITY», «POLKST» «ZIPplus4» This notice applies to your vehicle: «VIN» Dear «POLKNAME»: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Our records indicate YOUR UNIT HAS NOT BEEN REMEDIED. Please DO NOT ignore this notice! Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model 2019-2022 Cougar Travel Trailers. 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. It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash. Keystone
representatives have been in contact with the staff at your selling dealership regarding this situation. The remedy will be to notch the existing outrigger to provide clearance for the tire and an additional outrigger will be added between the two tires over the center spring hanger. The service and parts required for this corrective action will be provided at no charge to you. Reason for this recall What we will do RECREATIONAL VEHICLE SAFETY RECALL NOTICE Safety Recall: 22V-209 Safety Advisory: 22-430 October 20, 2022 PO Box 2000 – Goshen, IN 46527-2000 Phone: (574) 535-2100 – Fax: (574) 535-2199 www.keystonerv.com Customers should unload all cargo and empty holding tanks (fresh water, grey water, black water, and water heater) and take their unit to an authorized dealer for remedy. 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. BE ADVISED – Damage caused by failure to have the recall remedy completed will be the responsibility of the owner. 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 1-888-327- 4236 (TTY: 1-800-424-9153; or go to http://www.nhtsa.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 cc: National Highway Traffic Safety Administration (NHTSA) What we need you to do If you have questions
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SAFETY ADVISORY # 22-430 Cougar 29FKD Outriggers Keystone is conducting a voluntary RECALL notification campaign in accordance with the National Highway Transportation and Safety Act. It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash. Models Included: Year Model Serial Number Range 2019 2020 2021 2022 Cougar 29FKD KV510568 – KV510568 LV501245 – LV509098 MV501156 – MV512901 NV500784 – NV505003 Parts Required: 2 – KRV # 501127- Frame – Outrigger – Bolt On – 13.50″ x 6.88″ x 1.5″ (This part may be ordered in bulk without a VIN) Tools Required: – Screw gun – 3/8” nut driver – reciprocating saw or grinder with cut off wheel 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 inspect both front tires and check for damage. Cut out the outrigger at each front tire to allow for minimum of 3” of clearance, then add the bolt-on outrigger above the center spring hanger on each side of the unit. REPAIR INSTRUCTIONS Step 1 Unload the cargo area, empty the fresh and holding tanks. The trailer must be unloaded in order to get an accurate measurement between the tire and the outrigger. Step 2 Locate the trailer on a level, flat, hard surface. Chock the wheels. Keystone
RV Company 4/28/22 Safety Advisory 22-430 Page 2 of 3 Step 3 Using a reciprocating saw, cut a notch in the bottom side of the outrigger located above the tires on the off door side of the unit. Cut the notch to allow 3” of clearance between the tire and the outrigger, Figure 1. Touch up/spray paint the outrigger as needed. Step 4 In between the wheels and above the middle spring hanger on both sides of the frame, add KRV # 501127 – Frame – Outrigger – Bolt On – 13.50″ x 6.88″ x 1.5″ using (3) ¼” – 14 x 1” self-drilling hex screws into the frame rail and (1) 3/8” x 1 ½” lag bolt in the outer-most hole of the floor, see Figure 2. Step 5 Proceed to warranty reimbursement. Fig. 2 Fig. 1 Safety Advisory 22-430 Page 3 of 3 WARRANTY REIMBURSEMENT REPAIR Submit the claim on Key Express using Flat Rate Code # 7143042A In the Complaint section note: Safety Advisory # 22-430 In the Cause section note: Safety Advisory # 22-430 In the Correction section note: Cut existing outrigger for proper clearance. Installed bolt-on outriggers above center spring hanger. The amount of time authorized for this repair is 1.0 hour. PARTS DISPOSITION No part return. Please call Keystone
RV Customer Service at 866-273-1454 if you have any questions.
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PO Box 2000 – Goshen, IN 46527-2000 Phone: (574) 535-2100 – Fax: (574) 535-2199 www.keystonerv.com IMPORTANT SAFETY RECALL «Owner_name» «Street» «Street_2» «City», «State» «Zip» 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 2019-2022 Cougar Travel Trailers. 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. It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash. Keystone
representatives have been in contact with the staff at your selling dealership regarding this situation. The remedy will be to notch the existing outrigger to provide clearance for the tire and an additional outrigger will be added between the two tires over the center spring hanger. The service and parts required for this corrective action will be provided at no charge to you. Customers should unload all cargo and empty holding tanks (fresh water, grey water, black water, and water heater) and take their unit to an authorized dealer for remedy. 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. 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 1-888-327- 4236 (TTY: 1-800-424-9153; or go to http://www.nhtsa.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 cc: National Highway Traffic Safety Administration (NHTSA) Reason for this recall What we will do What we need you to do If you have questions RECREATIONAL VEHICLE SAFETY RECALL NOTICE Safety Recall: 22V-209 Safety Advisory: 22-430 May 13, 2022
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PO Box 2000 – Goshen, IN 46527-2000 Phone: (574) 535-2100 – Fax: (574) 535-2199 www.keystonerv.com SAFETY ADVISORY 22-430 «Dealer_name» ATTN: Service Manager «Street» «Street_2» «City», «State» «Zip» «Country» Dear «Dealer_name», Keystone RV Company has decided that a defect which relates to motor vehicle safety exists in certain model 2019-2022 Cougar Travel Trailers. As a result, Keystone
RV is conducting a safety recall. It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash. The vehicles included in the recall are: Year Model Serial Number Range 2019 2020 2021 2022 Cougar 29FKD KV510568 – KV510568 LV501245 – LV509098 MV501156 – MV512901 NV500784 – NV505003 Our records indicate unit(s) sold or in your present lot inventory fall within this range, which will require immediate preventative action. Important: If some of the units are still in your inventory, Federal Law requires you to complete the recall service on those units before retail delivery. The unit VIN(s) our records indicate are presently in your inventory or have been sold are as follows: «VIN1» «VIN2» «VIN3» «VIN4» «VIN5» «VIN6» «VIN7» «VIN8» «VIN9» «VIN10» «VIN11» «VIN12» «VIN13» — Serial numbers with ‘*’ have been retail sold — Claims for the units which have been serviced must be submitted. Claims submitted will be used by Keystone
to record recall service completions and provide dealer payments. Enclosed is a copy of the Safety Advisory #22-430, which details how to remedy the situation and the proper reimbursement procedures. We apologize for any inconvenience this situation may cause and greatly appreciate your cooperation. Should you have any questions or concerns regarding this correspondence or the enclosed Safety Advisory, please feel free to contact us. Sincerely, KEYSTONE
RV COMPANY cc. National Highway Traffic Safety Administration (NHTSA) cc. Transport Canada Reason for this recall RECREATIONAL VEHICLE SAFETY RECALL NOTICE Safety Recall: US: 22V-209 CAN: 2022-161 Safety Advisory: 22-430 May 13, 2022
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-209 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Keystone RV Company Submission Date : MAR 31, 2022 NHTSA Recall No. : 22V-209 Manufacturer Recall No. : 22-430 Manufacturer Information : Manufacturer Name : Keystone
RV Company Address : PO Box 2000 2642 Hackberry Drive Goshen IN 46527 Company phone : 574-535-2100 Population : Number of potentially involved : 513 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2019-2022 Keystone
Cougar 29FKD Vehicle Type : TRAILERS Body Style : Power Train : NR Descriptive Information : 29FKD floor plan Production Dates : MAR 22, 2019 – FEB 01, 2022 VIN Range 1 : Begin : 4YDT29F26KV510568 End : 4YDT29F26KV510568 ✔ Not sequential VIN Range 2 : Begin : 4YDT29F21LV501245 End : 4YDT29F2XLV509098 ✔ Not sequential VIN Range 3 : Begin : 4YDT29F20MV501156 End : 4YDT29F27MV512901 ✔ Not sequential VIN Range 4 : Begin : 4YDTCGP20NV500784 End : 4YDTCGP24NV505003 ✔ Not sequential Description of Defect : Description of the Defect : It has been decided that on certain Cougar 29FKD Travel Trailers, the tires may come in contact with an outrigger. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Under certain conditions during travel, if the tires make contact with the outrigger causing a tire blow out, it can lead to an increased risk of personal injury or vehicle crash. Description of the Cause : The outrigger was installed incorrectly allowing the tire to come into contact under certain conditions over time. Identification of Any Warning that can Occur : Visible tire damage. Involved Components : Part 573 Safety Recall Report 22V-209 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : 29FKD Frame Component Description : Frame – CGHT29FKD – TT – 2019 – 8″ JR I Beam – 1 G4 Slide – 1 Ram
Slide – w/ Accessory Receiver – w/3.0 Component Part Number : 630175 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 3/14/2022 – A claim was received that a Cougar 29 FKD had a tire that was damaged due to hitting an outrigger. A claim review was initiated that yielded 2 similar claims that had been misdiagnosed as suspension issues. Investigation into scope and range opened. 3/29/2022 – Investigation concluded and scope and range completed. Description of Remedy : Description of Remedy Program : The remedy will be to notch the existing outrigger to provide clearance for the tire and an additional outrigger will be added between the two tires over the center spring hanger. Manufacturer Reimbursement Plan on file as of 10/07/2020. General reimbursement plan to be updated every two years. New vehicles are covered under warranty. How Remedy Component Differs from Recalled Component : The existing outrigger will be notched out to provide clearance for the tire and an additional outrigger will be added between the two tires over the center spring hanger. Identify How/When Recall Condition was Corrected in Production : Units in the range were older builds and shipped prior to the decision to recall. Recall Schedule : Description of Recall Schedule : Keystone
will notify the dealers and owners of the recreational vehicles Part 573 Safety Recall Report 22V-209 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 by letter. A final copy of the owner letter will be provided to NHTSA, along with the dealer repair procedures. Planned Dealer Notification Date : MAY 23, 2022 – MAY 23, 2022 Planned Owner Notification Date : MAY 23, 2022 – MAY 23, 2022 * NR – Not Reported
SEOCONTENT-END
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