NHTSA Complaint #10509325 — 2009 FOREST RIVER BERKSHIRE

(REPORT PREVIOUSLY SUBMITTED 18 APRIL BUT MAY HAVE INADVERTENTLY BEEN DELETED). AT ABOUT 31,600 MILES ON MY RV (2009 FOREST RIVER BERKSHIRE MOUNTED ON A FREIGHTLINER CHASSIS WITH CUMMINS 350HP ENGINE), THE ENGINE SUDDENLY OVERHEATED. DURING REPAIR AT A FREIGHTLINER FACILITY, THREE OF FOUR RETAINING BOLTS WERE DISCOVERED BROKEN ON THE FAN HUB MOUNTED ON THE BACK OF THE ENGINE; THE FOURTH HAD BACKED OUT SEVERAL THREADS AND THE FAN TILTED INTO THE SHROUD AND SEIZED IN PLACE. FREIGHTLINER REPAIR TECHNICIAN STATED THEIR FACILITY HAD MADE SEVERAL REPAIRS ON CUMMINS/FREIGHTLINER CHASSIS RVS; THE FAILURE OCCURS WITH SOME FREQUENCY; THE BOLTS AND DESIGN OF FAN HUB APPEAR TO BE INADEQUATE FOR LOADS APPLIED BY THE SERPENTINE ACCESSORY BELT; AND THAT FAILURE OF ALL FOUR BOLTS COULD SHATTER THE FAN BLADES WHEN IT SEIZES IN THE SHROUD RESULTING IN SHRAPNEL DAMAGE TO THE RADIATOR AND SEVERED ELECTRICAL AND FLUID LINES. FURTHER CONSEQUENCES COULD INCLUDE A NEED TO QUICKLY EXIT TRAFFIC FLOW TO AVOID BECOMING A COLLISION HAZARD. FROM MY UNDERSTANDING, THE FAN HUB, FAN, RADIATOR AND OTHER ACCESSORIES ARE ADDED BY FREIGHTLINER TO THE CUMMINS ENGINE DURING CHASSIS MANUFACTURE. REPAIR REQUIRES CONSIDERABLE AND EXPENSIVE REMOVAL OF ENGINE ACCESSORIES. USE OF THIS CUMMINS/FREIGHTLINER CHASSIS CONFIGURATION BY OTHER COACH MANUFACTURERS IS UNKNOWN. TECHNICIAN ON MY REPAIR DRILLED AND TAPPED A FIFTH BOLT TO STRENGTHEN THE FAN HUB. ONLINE FORUM INQUIRY AND INTEREST FROM OTHER OWNERS SUGGESTS SIMILAR EXPERIENCES. ONE OTHER OWNER LEARNED THAT FREIGHTLINER IS AWARE OF THE PROBLEM, THAT THEY HAVE NO RECALL BUT THEY HAVE A FIVE BOLT FAN HUB FOR PURCHASE THAT EVIDENTLY ADDRESSES A LOAD FAILURE PROBLEM WITH THE FOUR BOLT DESIGN. *TR