2015 Forest River Shasta

The Office of Defects Investigation (ODI) opened this investigation after receipt of Defect Petition ES15-004654.The petition alleged eleven (11) separate issues.Six (6) of the issues related to vehicle design or construction.The other five (5) related to corporate safety culture.ODI considered each issue separately during it's evaluation.An outline of the issues follows.Additional details are included in the attached Evaluation Report.Four (4) issues were addressed with recalls: Window failuresRecall 15V-553 Wheel well/Suspension/RimsRecall 15V-552 Passenger tire failures Recall 15V-369 Dinette bed failures Recall 16V-218One (1) issue was addressed with a Technical Service Bulletin (TSB). Body separation from frame.OEM TSB # 53-05112016-0191.One (1) issue, Door Lock Failures, was not considered a safety issue as NFPA Standard 1192 requires multiplemeans of egress.The remaining five (5) issues, listed below, were either directly or indirectly addressed by a Consent Order issued July 8, 2015. (1) Questionable record keeping practices on serious defects (2) Shasta & Dealer dismissing safety concerns reported by owners (3) No proactive plans to address known defects (4) Poor service management practices, owners have no support (5) Barriers [to customer feedback]This investigation is closed. The agency is actively involved with Forest Riverto improve its corporate safety culture and reserves the right to take further action if warranted.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following complaint identification numbers:10715617, 10716585, 10716724, 10716729, 10716759, 10716854, 10717124, 10717213, 10717214, 10717217, 10717218, 10721743, 10721784, 10721793, 10721800, 10721913, 10722087, 10722308, 10730470, 10733176, 10733186, 10734026, 10735477, 10744818, 10745868,10758568, 10758570, 10758572, 10758578, 10758579, 10758582, 10758584, 10758587, 10758591, 10758593, 10759735, 10785358, 10786649, 10786660, 10846348, 10854917

I HAVE A TRAVEL TRAILER WITH 15' WHITE PAINTED STEEL SPOKE WHEELS, AFTER A YEAR ONE HAD A AIR LEAK WHERE THE RIM AND SPOKES ARE WELDED TOGETHER, ABOUT 6 MONTHS LATER ANOTHER WHEEL HAD THE SAME THING HAPPEN, I ENDED UP PUTTING INNERTUBES IN THEM. IN SEPT. OF THIS YEAR WHILE TRAVELING AT 65MPH ON HIGHWAY 80 IN IOWA, WE HAD A WHEEL/TIRE FAILURE SINCE WE NEVER FELT ANYTHING WHEN IT HAPPENED WE DIDN'T PULL OVER RIGHT AWAY, I THOUGHT THE NOISE I HEARD WAS A TRUCK PASSING US BUT AFTER IT PASSED THE NOISE WAS STILL THERE. WE PULLED OVER TO FIND THAT ONE TIRE AND RIM WAS MISSING ONLY THE SPOKES WERE LEFT STILL BOLTED TO THE HUB. THE TIRES WERE INFLATED TO 65 PSI COLD THAT MORNING, THE LUG NUTS WERE CHECKED FOR TIGHTNESS ALSO, WE HAD BEEN ON THE ROAD FOR AROUND 5 HOURS. WE NEVER HEARD ANY NOISE THAT I WOULD THINK WAS A TIRE GOING BAD, THE FLAP, FLAP, FLAP SOUND YOU HEAR WHEN A TRUCK GOES BY WITH A BAD TIRE. THERE WAS NOT ANY DAMAGE TO THE BOTTOM OF THE TRAILER OR MARKS THAT MAY HAVE BEN MADE BY A TIRE COMING APART, THE DAMAGE TO THE TRAILER WAS TO THE PLASTIC FENDER AND METAL IT WAS SCREWED TO. I THINK THAT MAYBE THERE WAS A PROBLEM WITH THE WHEEL MANUFACTURE, THAT THE WELDS WERE NOT AS GOOD AS THEY SHOULD HAVE BEEN. IT WAS SUGGESTED I CONTACT YOU IN CASE THIS PROBLEM IS BIGGER THAN JUST MY WHEELS. I HAVE PHOTOS OF THE AFTERMATH IF NEEDED.

NHTSA ID

11142321

Incident

Sep 15, 2018

Mileage

8,000 mi

FRAME IS NOT STABLE. FLEXING OF FRAME ALLOWS FRONT OF TRAILER TO MOVE FORWARD. THE FRONT WALLS SEPARATING FROM FRAME. LAG BOLTS INSUFFICIENT TO HOLD TRAILER ON FRAME. WHILE BACKING ON AN INCLINE, THE TRAILER FLEXED AND MADE CONTACT WITH MY PICKUP TRUCK.

NHTSA ID

11073560

Incident

May 23, 2017

Mileage

3,500 mi

THE FRAME WELDS WERE INADEQUATE AND HAVE BROKEN AWAY ON THE FRONT PART OF THE TRAILER NEAR THE TONGUE. THE CENTER CROSS MEMBER BETWEEN THE TONGUE IS DANGLING. IT IS A 2015 SHASTA 1961 RE-ISSUE 16 FOOT TRAILER. IT IS CLEARLY AN EXAMPLE OF SHODDY WORKMANSHIP, AND IS DEFINITELY A DANGEROUS SAFETY ISSUE. I AM NOT SURE WHEN THIS HAPPENED. I ONLY BECAME AWARE OF THE PROBLEM AFTER OTHER OWNERS OF THIS SAME MODEL TRAILER BROUGHT THE PROBLEM TO LIGHT. THIS IS NOT THE FIRST SAFETY ISSUE WITH THESE TRAILERS

NHTSA ID

11048005

Incident

Oct 10, 2017

MOVEMENT OF FRAME AWAY FROM TRAILER BODY. MOVEMENT OF TRAILER TONGUE AWAY FROM BODY AND SEPARATION OF BENCHES IN FRONT OF TRAILER INTERIOR. LAG SCREWS SHEARED OFF IN FRONT OF TRAILER WHERE THEY GO HORIZONTALLY THROUGH FRONT BODY AND IN TO FRAME OF TRAILER. WELDS MISSING FROM FRONT FORK OF TRAILER. FORK WELDED ON ONE SIDE ONLY. HORIZONTAL MOVEMENT OF TRAILER TONGUE AND FORK FROM BODY WHEN ON JACK STANDS.

NHTSA ID

11040209

Incident

Oct 15, 2017

THE 19' FOOT TRAVEL TRAILER HAS SEPARATION OF THE INSIDE WALL AT FLOOR AND DINETTE BENCH FROM THE FRAME.

NHTSA ID

11033416

Incident

Aug 1, 2016

AFTER NUMEROUS PHONE CALLS AND EMAILS TO GET LAZY DAYS IN COLORADO TO COMPLETE REQUIRED AND AGREED UPON RECALL WORK DONE ON MY CAMPER, THEY CONTINUE TO FAIL TO DO SO. THEY USE STALL TACTICS TO DISCOURAGE ME FROM GETTING THE WORK DONE. MY CAMPER HAS BEEN SITTING ON THEIR LOT FOR 4 WEEKS NOW AND THEY STILL HAVE NOT ORDERED PARTS. THIS HAS BEEN GOING ON SINCE 2015 WHEN I BOUGHT THE CAMPER NEW FROM THEM. MY CAMPER WAS ON THEIR LOT FOR 5 MONTHS AT THAT TIME FOR RECALL WORK AND OTHER WORK. I DON?T NEED FREE STORAGE, I HAVE 5 ACRES AT MY HOUSE TO STORE IT ON. I HAVE CONTACTED THEM ON 12/14/16, 1/4/17, 1/7/17, 2/17/17, 2/15/17, 2/28/173/1/17, 4/3/17, 4/4/17, 4/6/17, 4/8/17. SOMETIMES I RECEIVE A RESPONSE SOMETIME I DO NOT. MY LAST REQUEST 4/6/17, WAS TO MEET PERSONALLY WITH MANAGERS TO GET AN UPDATE ON PARTS ORDERED AND WHEN I COULD EXPECT THE RECALL WORK ON MY CAMPER TO BE COMPLETED. I HAVE NOT RECEIVED A RESPONSE. I HAVE A MORE DETAILED LETTER, BUT IT GOES OVER YOUR CHARACTER COUNT LIMIT. RECALLS ARE FOR: 2015 FOREST RIVER SHASTA AIRFLYTE CAMPER TRAILER VIN #[XXX] RECALLS: NHTSA # 16V-218 NHTSA # 15V-552 NHTSA # 15V-553 NHTSA # 15V-369 FOREST RIVER TECHNICAL SERVICE BULLETIN- DOCUMENT CONTROL # 53-05112016-0191 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10971644

Incident

Apr 8, 2017

NHTSA RECALL NUMBER:15V553 I TOOK MY CAMPER IN FOR WINDOW RECALL WORK IT SAT FROM JAN TILL MID APRIL AND WAITED FOR THE WINDOWS TO COME IN TO BE REPLACED AND I WAS TOLD THEY ALL WERE REPLACED. THE CAMPER WAS PARKED AND I WHEN I OPENED THE WINDOWS TO LET SOME FRESH AIR IN THE CAMPER THE TOP WINDOW GLASS PULLED LOOSE FROM ITS ALUMINUM HINGE AND WAS DANGLING FROM THE MECHANISM THAT OPENS AND CLOSES THE WINDOW. I CONTACTED SHASTA WARRANTY DEPARTMENT ONCE THE WINDOW FELL OUT AND HE LOOKED UP MY CAMPERS REPAIR HISTORY AND THE ONLY WINDOWS THAT DIDN'T PASS INSPECTION AND HAD TO BE REPLACED WAS BACK WINDOW AND THE 2 UP FRONT. I WILL BE RETURNING FOR A WINDOW REPLACEMENT. SO IT LOOKS LIKE EVEN IF THE WINDOWS PASS THE INSPECTION THEY STILL CAN FALL OUT...

NHTSA ID

10863927

Incident

May 9, 2016

TRAILER ENTRY DOOR BECOMES JAMMED AND IS NOT ABLE TO BE OPENED FROM THE INSIDE OF THE TRAILER. THIS HAPPENED ON SEVERAL OCCASIONS. THIS POSES A SERIOUS SAFETY RISK FOR ANYONE THAT MIGHT BE TRAPPED INSIDE THE TRAILER.

NHTSA ID

10862396

Incident

Jun 1, 2015