2019-2024 FR3 and Georgetown Propane tank bracket failure recall just issued

[NXR]

To the admins: I am duplicating this post in the Georgetown section because this is a critical issue and I believe it belongs in both Owner sections. Your call, of course.

Potential Number of Units Affected 6,966

Summary
Forest River, Inc. (Forest River) is recalling certain 2019-2024 Georgetown and FR3 Class A motorhomes. The liquid petroleum gas (LPG) tank mounting brackets may break, which can result in the LPG tank becoming dislodged and damaged.

Recall notice link: https://static.nhtsa.gov/odi/rcl/2024/RCLRPT-24V103-7106.PDF

There's not too much information on the actual repair process yet. While MORryde knows what they did to add reinforcement to new coaches, someone has to develop, test, and document the process to retrofit the reinforcements to all of the variations of existing motorhomes. That is not a process that can be rushed.

Note that dealers will NOT be notified until March 24, 2024 so your dealer will NOT have any idea what to do for a repair until then.

If you want to discuss this with your dealer you could email them the PDF I attached to this post. It has several pictures of actual failures people have experienced.

Remember, the number of reported failures is currently in the single-digits, like one-tenth of one percent so far. I'm sure that number will increase but this likely is a "Low probability-High impact" condition.

Note that the NHTSA and FR acted off of people who filed complaints with the NHTSA and Forest River. No one with a Georgetown or FR3 manufactured prior to March 2019 filed a complaint.

Does that mean none of the earlier ones are potentially affected? It is unlikely that the very first person to experience a problem really was the first person to have the condition AND reported it to the NHTSA.

Me, I'd be looking at the pics in this PDF and checking mine even if it is outside of the recall range. This is something an owner can do. You MUST clean the brackets and area and examine the brackets from the top and bottom using a bright flashlight. If you find a problem please file an NHTSA complaint. The recall can be expanded if necessary.

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Thanks to everyone who filed an NHTSA complaint about their failures. Your action is helping to keep other FR3 families safe.

You'll note that MORryde decided to improve the tank mounting as of December 11, 2023. That means Forest River definitely took this issue very seriously.

And especially thanks to Forest River for taking care of this issue despite the cost to FR.

 

[DaFishFR3]

Thank you for posting this and thank you Forest River for addressing and correcting the issue. In light of issues that other manufactures are having now, this is refreshing and appreciated.

 

[DRFR3]

Thanks for providing all the information Ray!

 

[NXR]

Thank you for posting this and thank you Forest River for addressing and correcting the issue. In light of issues that other manufacturers are having now, this is refreshing and appreciated.

Well put. It's definitely sad but the fact that Forest River immediately jumped on the problem after the NHTSA complaints were filed (per some dates in the NHTSA recall notice) is a great testament to me for how Forest River handles issues like this. Once again we realize we bought the correct motorhome.

No one screws up on purpose but everyone screws up. How the problem is handled is what's important to me.

Ray

 

[NXR]

The NHTSA has released two additional docs on the propane mounting bracket failures.

Notice to dealers: https://static.nhtsa.gov/odi/rcl/2024/RCMN-24V103-9383.pdf

There seems to be a typo in that letter because it says the earliest model year is 2019 yet the recall covers Georgetown and FR3 models built from November 16, 2017 through December 14, 2023.

I'd be willing to bet that FR was not building 2019 model year motorhomes in late 2017 but maybe.

The Remedy Instructions and TSB (technical service bulletin): https://static.nhtsa.gov/odi/rcl/2024/RCRIT-24V103-4903.pdf

But all it is is an inspection and how to submit photos. There are no repair instructions at all because FR will supply those on an individual basis.

They also spelled "perimeter" as "parameter" on page 2 but it did pass the spell check.

An open question is whether there should be weld on 100% of the two vertical and horizontal edges of each bracket. The document seems to indicate so but no one has posted a pic that was that way. Even the Forest River Motorized Division pic of a gusset-reinforced L bracket showed "stitch" welds in spots and not continuous welds.

Notably missing is any requirement to look for cracks on the propane tank mounts that are welded to the tank itself when the tank was manufactured. At least two people have had cracks in those.

But it's a start.

Ray

PS: The VIN Search for recalls does not yet show a recall for our VIN. That probably won't go active until the letters are actually mailed out.

 

[NXR]

Pics of the propane tank mounting "L" brackets for recall 24V-103 can now be uploaded to Forest River

There is a QR code in the Owner Notification Letter found here: https://static.nhtsa.gov/odi/rcl/2024/RCONL-24V103-4277.pdf

And that QR code takes you to this web site to upload the photos: https://forestriverinc.com/campaign/24V103

There is a box to check if you think you may have problems.

Let the uploading begin!

Some people who uploaded pics in the last few days have already gotten a response from Forest River. When the recall letters get mailed out very soon their response time may slow and dealer delays may increase.

Beat the rush.

 

[NXR]

Folks, one item that seems to be missing from the inspection process is to check the tightness of the four attaching bolts and nuts.

The pic is of one person's 2023 Georgetown GT7.

A person with a 2021 FR3 forum looked at their brackets and found their front inside bolt was completely missing and the rear inside bolt was loose. A person with a 2023 Dynamax Europa Super C found one end of their tank hanging down because bolts bolts had fallen out even though they are not part of this recall. We found our two outside bolts needed tightening but were not yet "loose" while the two inside bolts were tight.

If you are doing your own inspection please take a look at the attaching bolts and nuts and try to tighten each one. Also consider adding a third bolt in the normally-unused center hole. Our bolts are 2 1/2" long with a 7/16" thread and Grade 5. I used a nylon locking nut with a flat washer on the top and bottom in each center hole. Those are easily available at any hardware store.

Some people seem to have had a wire run through that center hole, though.

If FR says your pics are fine but you did not check the bolt tightness you could still have a problem. Their directions do not specifically say to look at the brackets from underneath or attempt to tighten each bolt and that's probably just an oversight. A missing bolt is fairly obvious but a loose bolt may not be noticed visually.

FWIW,

Ray

 

[NXR]

Propane tank mounting recall: Actual repair procedure released

https://static.nhtsa.gov/odi/rcl/2024/RCRIT-24V103-9509.pdf

The interesting part is that the new brackets will no longer be welded on. The existing brackets have the horizontal section cut off and the new bracket is placed over the remaining vertical part and bolted in place with 1/2" bolts.

However, there is nothing in the TSB about checking to assure that the factory brackets were properly placed. On ours, the factory brackets were welded in place too far inward and part of the propane tank hits on other support structure.

That means the bolts cannot draw the tank up flat against the bracket horizontal section.The light shining through in the one pic is due to the tank misalignment because the bolts are tight. In addition, tightening the tank mounting bolts when the tank is not flush against the bracket means the tank mounting flange may be put under stress or even bent. Or maybe this is completely irrelevant; I don't know.

If yours is the same way, be certain to ask your dealer about realigning the tank. Have them check with Forest River before actually doing anything different, of course.

Ray

 

[Twinboat]

I'm in Texas heading home to NY, in my FR3. My daughter got the recall notice, so I thought i should take a good look.

Found no cracks but 1 tank mouning bolt was rattling loose and the other 3 were snug or finger tight.

Got them pretty tight with my limited tools, but it should make it to a dealer in NY.

 

[NXR]

I'm in Texas heading home to NY, in my FR3. My daughter got the recall notice, so I thought i should take a good look.

Found no cracks but 1 tank mounting bolt was rattling loose and the other 3 were snug or finger tight.

Got them pretty tight with my limited tools, but it should make it to a dealer in NY.

Good work. I know you know how to evaluate welds. Do your brackets look like they have a sufficient number of stitch welds? You know, to get to New York.

The fellow who ground out the crack and welded our rear bracket did not like the existing welds so he added extra welds to the front and rear bracket in addition to adding gussets to the rear bracket. Still, on this 1,300 mile trip I was nervous and checked the tank at each stop. While here, I added the four corner safety chains and I am feeling a lot better about the trek home.

Ray

 

[Twinboat]

The welds are not robust but still look good.

We're going to try to get home with less then 1/2 tank of propane.

 

[SR0981]

LP Tank cracked too

Not only do I not have the end wields, but my tank is cracked as well. Forest river has approved both the recall repair and the tank replacement.

 

[NXR]

Not only do I not have the end wields, but my tank is cracked as well. Forest river has approved both the recall repair and the tank replacement.

Please file an NHTSA complaint. My tank mounting flange and at least two others have cracked in the same place but they are not part of the recall and at least one person was turned down for a tank replacement. Me and the others filed separate complaints for that crack.

See: https://www.nhtsa.gov/report-a-safety-problem#index

My pics to FR also showed I do not have the end welds yet mine were pronounced as OK plus I had to have a crack welded. I appealed and got a phone call that I was now approved for the new brackets. But my VIN still does not show up as needing a recall.

FR should re-evaluate all pics and rethink their entire process. People are posting near-identical pics on another forum and some got denied while others got approved.

Makes no sense to me.

Ray

 

[Twinboat]

Just took 4 pictures and submitted them to Forest River for the tank recall.

While reading the notice, I see in 2 places that the repair takes . ( point ) 20 hours. That's like 13 minutes.

Anybody have the repair done yet ?

 

[NXR]

A dealer can get reimbursed 0.2 hours for taking the pictures on behalf of the owner and uploading them. If the repair is approved then there is another four hours allocated.

Ray

 

[SR0981]

So, They performed the repair at my local Holiday World and they did a good job. The Tank had a crack in it as well and it was replaced under the warranty from what I was told as the tank itself wasn't part of the recall (again what I was told). I dropped it off in the morning and picked it up the next morning. They even gave me a full tank of propane. Regardless, it is done and I'm happy with the repair.

 

[NXR]

Please file an NHTSA complaint about the crack in the tank itself. Ours and others have cracked at the outside rear as well and were told the tank is not part of the recall.

https://www.nhtsa.gov/report-a-safety-problem#index

I included pics of our tank crack in my NHTSA complaint but more complaints are needed so everyone who has a cracked tank flange can get theirs fixed.

Ray