2017 Newmar Dutch Star

My DEF sensor failed which required towing on Interstate 80 in a highly congested area. This same failure has happened to many other motorhomes and trucks. It creates a very unsafe situation which needs to be corrected. Please require the manufacturer to correct the flaw and recall all in use. Thank you.

NHTSA ID

11521780

Incident

May 12, 2023

DEF Head Failure - Spartan Chassis.

NHTSA ID

11425343

Incident

May 1, 2021

RV WENT INTO 5MPH DERATE DUE TO DEF HEADER MALFUNCTION. I WAS VERY LUCKY TO BE IN AN RV PARK, HOWEVER THERE IS NO WAY TO REPLACE THE DEF HEADER WITHOUT RAISING THE RV (DUE TO THE LOCATION OF THE TANK), SO IT COULDN'T BE REPLACED THERE. I HAD AN APPOINTMENT TO REPLACE THE DEF HEADER AT FREIGHTLINER OF HOUSTON, DUE TO THE WARNING LIGHTS. HOWEVER WHEN I STARTED TO DRIVE THERE FOR THE APPOINTMENT, I FOUND THE RV WOULD NOT GO OVER 5MPH. SINCE THE DEALER WAS 60 MILES AWAY (AND IT WAS THE NEAREST ONE), THERE WAS NO WAY I COULD MAKE IT.

NHTSA ID

11415723

Incident

Nov 20, 2020

Mileage

21,215 mi

I OWN A 2017 NEWMAR DUTCH STAR MOTOR HOME ON A FREIGHTLINER CHASSIS. THE DIESEL EXHAUST FLUID (DEF) SENSOR (DEF HEAD) HAS FAILED TWICE. THE FIRST FAILED AT 14,795 MILES AND WAS REPLACED ON 9/24/18. THAT HEAD LASTED ANOTHER 15,000 MILES AND FAILED AT 31,218 AND WAS REPLACED ON 11/25/2020. EACH HEAD LASTED ABOUT 15,000 MILES OR 2 YEARS. THE PART IS MADE BY SHAW DEVELOPMENT WHICH HAS NOT ANSWERED REPEATED ATTEMPTS FOR INFORMATION. AS PART OF THE EMISSIONS SYSTEM, FREIGHTLINER HAS REPLACED BOTH HEADS UNDER THE 5 YEAR FEDERALLY MANDATED WARRANTY ON EMISSION SYSTEMS. CUMMINS (WHICH MAKES THE ENGINE) ALSO IS INVOLVED IN EMISSIONS. THE THREE SEEM TO PASS THE BUCK FROM ONE TO THE OTHER LEAVING THE CONSUMER TO DEAL WITH THE SAFETY ISSUE OF DERATING AND COST AFTER THE WARRANTY. WHEN DEF SENSORS FAIL, THE ENGINE CAN GO INTO DERATE WHICH IS 5 MPH. THIS PROBLEM IS LEAVING MANY LARGE DIESEL ENGINE OWNED VEHICLES STRANDED, FROM MOTORHOMES TO LARGE OVER THE ROAD TRUCKS. I BELIEVE THEY ARE NOW ON GENERATION 6 DEF HEAD, AND FAILURES CONTINUE TO BE COMMON. SHAW DEVELOPMENT REFUSES TO TAKE CALLS OR EMAILS REQUESTING INFORMATION REGARDING THIS PROBLEM. THERE ARE NUMEROUS ONLINE POSTS OF SIMILAR ISSUES AND THOSE INVOLVED IN THE REPAIR BUSINESS TELL ME THIS IS A VERY COMMON FAILURE. MY UNDERSTANDING IS THAT DEF SENSORS MEASURE DEF CONCENTRATION PER REGULATIONS PASSED BY THE EPA IN 2016. THE PROBLEM IS THAT SHAW DEVELOPMENT HAS NOT DEVELOPED AN ADEQUATE TOOL TO FOLLOW THIS REGULATION WHICH IS CAUSING SAFETY ISSUES AND EXPENSE TO CONSUMERS.

NHTSA ID

11384355

Incident

Nov 25, 2020

Mileage

15,000 mi

WE HAVE HAD TWO DIESEL EXHAUST FLUID (DEF) HEAD FAILURES THAT HAVE REQUIRED REPLACEMENT OF THE DEF HEAD UNIT. THE FIRST SITUATION RESULTED IN A DERATING OF THE ENGINE, LIMITING OUR SPEED TO 4 OR 5 MPH WHILE ON THE INTERSTATE. THE VEHICLE HAD TO BE TOWED 200 MILES TO A SERVICE CENTER, THEN IT TOOK A WEEK TO OBTAIN REPLACEMENT PARTS. THE SECOND SITUATION HAPPENED WITHIN 5 MILES OF A SERVICE CENTER AND WE WERE FORTUNATE ENOUGH TO BE ABLE TO MAKE IT TO THE SERVICE CENTER. HOWEVER, WE ARE SEEING HUNDREDS OF SIMILAR SITUATIONS BEING POSTED TO RV FORUMS ON VARIOUS SOCIAL NETWORKS. A RECALL NEEDS TO BE MADE FOR ALL CUMMINS ENGINES THAT HAVE DEF SYSTEMS. AS PART OF THE SOLUTION, THE DESIGNS NEED TO BE CHANGED SO THAT THE ENGINES CAN CONTINUE TO RUN WITH THE DEF ERROR CODE RATHER THAN SENDING THE ENGINE INTO A DERATE SITUATION AS THIS PRESENTS A SEVERE HAZARD TO OCCUPANTS IN THE VEHICLE, AS WELL AS OTHER TRAFFIC ON THE ROAD. RV BUILT ON A PREVOST CHASSIS ALLOW NORMAL OPERATION OF THE ENGINE AND RV SPEED EVEN WITH THE DEF ERROR CODES.

NHTSA ID

11354123

Incident

Oct 3, 2019

Mileage

11,000 mi

DISCOVERED A FUEL LINE ROUTING THAT WAS RUBBING AGAINST THE LOWER PART OF THE ENGINE DURING AN INSPECTION AND SERVICE. I TIED IT BACK TO KEEP IT FROM RUBBING ALL THE WAY THROUGH THE FUEL LINE. THIS IS ON A FREIGHTLINER CHASSIS

NHTSA ID

11111332

Incident

Jul 11, 2018

Mileage

18,000 mi

Check for proper torque of all mounting bolts on all electric slideout motors. If any bolt is under- torqued, remove the bolt, and add blue LOCTITE® thread sealant to the bolt threads. If there is no washer on the nut side of the bolt, add a flat washer. Reinstall and torque all 5/16" bolts to 19 ft. lbs. and all 3/8" bolts to 33 ft. lbs.

Check for proper torque of all mounting bolts on all electric slideout motors. If any bolt is under- torqued, remove the bolt, and add blue LOCTITE® thread sealant to the bolt threads. If there is no washer on the nut side of the bolt, add a flat washer. Reinstall and torque all 5/16” bolts to 19 ft. lbs. and all 3/8” bolts to 33 ft. lbs.

Daimler Trucks North America has decided that a defect relating to motor vehicle safety exists in specific motorhomes built on Freightliner chassis (NHTSA #21V 326) based on Cummins recall (NHTSA # 21E 032). In response, Newmar Corporation is issuing recall NHTSA # 21V 506 and TC # 2021-427. On certain motorhomes, as described in Cummins recall 21E-032, the fuel rail assembly on the engine may develop leaks, which may result in an undetected prolonged diesel fuel spray. A leak involving spraying/misting fuel in the presence of an ignition source may increase the risk of fire.

The Shyft Group Inc. (Spartan Chassis) has decided that a defect relating to motor vehicle safety exists in specific motorhomes built on Spartan chassis (NHTSA #21V 319) based on Cummins recall (NHTSA # 21E 032). In response, Newmar Corporation is issuing recall NHTSA # 21V 372 and TC # 2021-303. On certain motorhomes, as described in Cummins recall 21E-032, the fuel rail assembly on the engine may develop leaks, which may result in an undetected prolonged diesel fuel spray. A leak involving spraying/misting fuel in the presence of an ignition source may increase the risk of fire.

Newmar Corporation has decided that a defect relating to motor vehicle safety may exist in specific coaches. On certain units, the windshield wiper mechanism may contact the brake light switch. If the brake light switch or wiring is damaged, the brake lights may not illuminate. Non-functioning brake lights may not alert other motorists of the driver’s intentions, increasing the risk of a crash.

Daimler Trucks North America LLC, has decided that a defect relating to motor vehicle safety exists in specific motorhomes built on Freightliner chassis NHTSA # 20V 404. In response, Newmar Corporation is issuing NHTSA Recall # 20V 421