2020 Forest River Flagstaff Problems

Subject Castle Rock Radial ST 205/75/R14 tire was running 10 degrees F. hotter (around 110 F) than the three sibling tires after about 30 minutes of travel. This had been the case for an earlier trip of approximately 275 interstate miles. All of these tires are original equipment and similarly used and maintained. The tire eventually exploded (see uploaded pics). Subsequent inspection shows a bubble had formed between layers of the tread portion of the tire. The failed tire is available for inspection. Tire pressure before traveling in the morning was 65 p.s.i. (this is consistently maintained when in use). The load/speed ratings of these tires are D105/101L or 2039 lbs/75 m.p.h. Our running speed is typically 65 m.p.h. or less. The trailer weighs approximately 5600 pounds as loaded. Likely due to a combination of this safety margin in both weight and speed along with a weight distributing hitch with a stabilizer bar, we did not lose control of the vehicle when the tire failed. We were able to pull onto the emergency apron of the interstate immediately and replace the failed tire with a spare tire (not the original spare). The original matching spare with zero miles of use on the road suffered a similar fate (bubble/tire layer separation) in 2022 (NHTSA Reference No. 11490675). The failed tire was taken to a nearby tire center where it was inspected and replaced with a new tire. Subsequent to this trip, the remaining three (3) OEM Castle Rock tires have been replaced due to their high failure rate (40% to date for us).

The contact owns a 2020 Forest River Flagstaff. The contact stated that when he had inspected the RV spare tire prior to a trip, he noticed that the spare had a blister on the tread. The contact stated that the blister extends from the inner side of the tread to the outer and is approximately five inches wide. The Tire DOT number: JUJTYMT 2819. The contact had taken the vehicle to a local dealer where it was not diagnosed the tire had been replaced. The vehicle had been repaired. The manufacturer had not been informed of the failure. The failure mileage was 0, the tire had never been used and was original equipment.

When forced to drive over a canvas tent bag, Due to traffic and road conditions. The tent bag wrapped around the drive shaft, ripped out the brake lines and the emergency brake lines damaged the master cylinder and damage the emergency brake mechanism in the cab of the RV. There should be protection under the vehicle so that does not happen! The loss of both types of brake systems could be catastrophic.

3500# axles added to a trailer with a gross weight of 3920#. Tires are severely worn on the inside from an undersized axel. Possible tire blow out if not corrected.

The fabric side wall failed to keep my daughter safe as she slept in the camper. She fell out of the camper onto the hard, cold ground while she was sound asleep. She could have been seriously injured. The Velcro on the fabric was secured to the camper frame.

When forced to drive over a canvas tent bag, Due to traffic and road conditions. The tent bag wrapped around the drive shaft, ripped out the brake lines and the emergency brake lines damaged the master cylinder and damage the emergency brake mechanism in the cab of the RV. There should be protection under the vehicle so that does not happen! The loss of both types of brake systems could be catastrophic.

The fabric side wall failed to keep my daughter safe as she slept in the camper. She fell out of the camper onto the hard, cold ground while she was sound asleep. She could have been seriously injured. The Velcro on the fabric was secured to the camper frame.