2021 Forest River FR3

The contact owns a 2021 Forest River FR3 built on a 2020 Ford F-53 Chassis. The contact stated while driving and exceeding 45 MPH, the contact noticed that the dashboard was bouncing. Additionally, the contact stated while driving at an undisclosed speed, the bottom of the dashboard fractured and separated along with the parts attached to the dashboard. The RV was taken to the dealer, where the cause of the failure could not be determined. The dealer provided an estimate for the repair. The dealer notified the manufacturer of the failure, but the manufacturer informed the dealer that the repair could not be covered because the RV was not covered under warranty. The RV was not repaired. The failure mileage was approximately 36,000.

NHTSA ID

11618460

Incident

Oct 7, 2024

Mileage

36,000 mi

LP brackets are cracked at the welding

NHTSA ID

11576757

Incident

Mar 11, 2024

Due to faulty welding of the supports for the onboard propane tank, the tank fell out the bottom of the rig on I-70 outside Kansas City on June 6 2023. The tank bounced around, knocking out one one of the drive shafts before bursting into flames. There was no warning before this happened as there are no sensors for that. With the rig being a total loss, there is no way to reproduce the problem. My insurance company hired a fire investigator, but findings were inconclusive due to the extent of the fire damage. I have since found others that have had this issue, but mine is the first that led to a fire that I am aware of. [XXX] . Forest River has been contacted, but they deny a problem exists. All five passengers made it out safely. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11553249

Incident

Jun 6, 2023

Our 2021 Forest River FR3 34DS is built on the 2020 Ford F53 V8 chassis. When bringing the RV in for other service, the Ford dealer noticed that one of the bolts was missing from the rear sway bar. Further inspection showed that the coupling used to attach the sway bar was seriously deformed. This had a negative impact on the steering/handling of the RV in windy weather and when being passed by semis, RVs, and local delivery box trucks. We had to wait about a month for the parts to come in and be installed. A quick google will show this is a wide-spread problem across multiple brands of RVs that are built on the F53 chassis. This seems like either a design issue or a need to torque those bolts to a specific value.

NHTSA ID

11438906

Incident

Aug 31, 2021

Our 2021 Forest River FR3 34DS is built on the 2020 Ford F53 Chassis with the V8 engine. Our unit was recalled for potentially insufficient axle lubricant. After Ford replaced the bearings, our anti-skid, ABS, and cruise-control stopped working with indicators showing that on the dash. The Ford dealer believes the problem is with the tone ring. It has been several months and the Ford dealer is unable to obtain a tone-ring. Meanwhile, the RV continues not to have these important safety features.

NHTSA ID

11438904

Incident

Aug 30, 2021

According to Ford's Final Notice of Recall 22V731: "In some of the affected vehicles, the rear stabilizer bar attachment bracket(s) weld-nuts may not be capable of supporting the required joint torque for this application and may have been damaged during the assembly process. During vehicle usage, the weld nuts attaching the rear stabilizer bracket may loosen, and the attachment bracket may break and/or the attachment bolts and the bracket may separate from the vehicle. It is possible that this may result in a road debris hazard."

According to the notice from Ford 22S62: In some of the affected vehicles, the rear stabilizer bar attachment bracket(s) weld-nuts may not be capable of supporting the required joint torque for this application and may have been damaged during the assembly process. During vehicle usage, the weld nuts attaching the rear stabilizer bracket may loosen, and the attachment bracket may break and/or the attachment bolts and the bracket may separate from the vehicle. It is possible that this may result in a road debris hazard.

The rear axle may contain an inadequate volume of lubricating oil. An inadequate volume of rear axle lubricant may result in rear wheel bearing damage potentially leading to bearing seizure. Bearing seizure may lead to rear axle or driveshaft failure. A rear axle or driveshaft failure may result in loss of vehicle motive power, loss of transmission park function, and loss of parking brake function, increasing the risk of a crash.

It was discovered that the manufacturing plant did not cut a stress relief line in the upper deck Driver Side and in on certain models, Passenger Side under the slide room(s). The upper deck in the Impression Fifth-Wheel needs to flex, without the "stress relief cut" the sidewall filon may crack under the slide room(s).