2021 Forest River Cherokee

I am the original owner of a 2021 Forest River Wolf Pack 325PACK13 fifth-wheel trailer (VIN: [XXX]), purchased new on [XXX]. The trailer is built on a Lippert Components chassis manufactured in September 2020. My trailer developed multiple structural cracks in the front overhang/pin box area of the frame. This is not a single crack. The damage includes multiple cracks in the steel chassis, separation between the fiberglass front cap and the trailer body, gaps between structural members beneath the floor, and movement throughout the front of the trailer. Because the pin box transfers all towing forces into the frame, I considered the trailer unsafe to tow and immediately removed it from service. This is a structural failure involving the primary load-bearing chassis, not cosmetic damage. I am concerned this defect could affect towing stability, structural integrity, and increase the risk of failure during highway travel. The trailer has remained at an authorized repair facility for approximately four months awaiting repairs. During that time, I have repeatedly contacted Forest River for updates, often daily, but have received virtually no meaningful communication. My calls have routinely gone unanswered or unreturned, and the repair facility has also struggled to obtain responses, significantly delaying repairs. I am concerned this may represent a broader safety issue affecting other Forest River trailers built on similar Lippert chassis. I respectfully request that NHTSA investigate whether these structural frame failures are occurring in other units and determine whether a safety-related defect exists that warrants corrective action. I have photographs documenting the multiple frame cracks, structural separation, repair records, warranty documentation, and communication records and will provide them upon request. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Tire size was ST 205 / 75 R 15. This tire experienced a significant belt separation failure that I fortunately noticed before departing our campsite. While doing a walk around inspection before departure, I noticed a severe tread deformity in the front passenger side tire on our camper. The tires were cold and the ambient air temperature was in the low 60's. Before removing the tire and wheel from the trailer, I checked the tire pressure on all 4 tires, and all were within 2 psi of the recommended 65 psi cold pressure, including the failing tire. I removed the wheel and tire assembly and deflated it for safety, and then took it to a local tires shop to replace the tire. They diagnosed it as belt separation and further stated that it would have likely failed with a blowout within a few miles if I hadn't caught it. The tire had an estimated 15,000 miles on it at the time, but had been professionally repaired for a screw puncture approximately 7,000 miles earlier.

The contact owns a 2021 Forest River Cherokee Toy Hauler. The contact stated that while driving at various speeds, the frame was flexing at the RV pin box location. The contact stated that while unhitching the trailer, the contact noticed that there was weld separation on the left and right sides of the tow hitch outer frame. Additionally, the contact stated that the cargo door holding the propane tank was opening unintendedly while driving. The trailer was taken to an independent mechanic, where it was diagnosed with spring damage, and the contact was informed that the cargo door that held the propane tank was opening unintendedly because the frame was flexing at the RV pin box location. The Lippert manufacturer that installed the frame was contacted and advised the contact to send pictures of the failure. The manufacturer, Forest River, was notified of the failure and advised the contact to apply gel in the weld gaps. The trailer was not repaired. The failure mileage was unknown.

ST 225/75R15 One driver side tire blew in May/2025 which caused extensive damage to the RV floor and sidewall. I replaced and did not file a claim. My family was in the tow vehicle when the blowout occurred. Debris was thrown across the highway and I had no room on the side of the highway to change the tire. Police called. Yesterday July 14/2025, the spare tire blew up all on its own while at a campground. It was on the back of the camper not being used. The spare tire cover was destroyed. Neighbors thought a propane tank exploded. Anybody walking by could have been seriously injured. I did a search and found a recall for these tires.

When I bought this camper I paid extra for an extensive warranty including the tires. On a recent trip I blew a tire on the trailer and contacted the warranty company. Was instructed to take the trailer and tire to an authorized service center. Upon doing so the service center notified me that the axles were bent because they were insufficient for the size of the trailer. The gentleman I spoke with said that regardless of what the tags read on the camper the axles were not sufficient for the load rating listed on the tag inside the camper. Thus they put excessive strain on the tires and one blew while I was traveling on the highway. He told me another one was ready to blow out. I reached out to the RV dealership where I bought the trailer and they referred me to the trailer manufacturer who denied any responsibility and claimed that the axles were sufficient for that trailer. This is a recurring issue with these travel trailers as I have friends who have the same models and one has already had to replace his axles because they bent and a tire blew out and damaged the side of his camper and the other one changed his tires and springs to help offset the weight issue. I even reached out to the axle manufacturer who supplied these components to the RV company and all they provided was this measurements I needed to order new axles. All I wanted from the RV manufacturer was even a pittance of an offer to help me with this issue but all they did was claim that all the parts were good and they weren't responsible. I have ordered new heavier duty axles and larger tires to accommodate the weight. As I stated the RV repair center that is working on my trailer said the axles were insufficient and the tires were actually too small for a trailer that size. Apparently the only way an RV company will do the right thing is if they are threatened with a lawsuit. Forest River has already been implicated in a lawsuit for other issues. So they are aware that they have issues!

The slide mechanism and gear rack are out of spec per their manufacturer of the component (schwintek inverted gear rack). On my unit the “shoe” part of the rack has failed (possibly because of improper installation) and I am afraid that if the slide is not secured by the gear rack that it could slip out while the vehicle is in motion. Lippert does have a TSB for this, but apparently doesn’t apply to my date range. Lippert TSB is 146-001-2022. Forest river tells me “this can happen over time from usage.” Lippert (schwintek mfg) says: “The concern appears to stem from an out-of-spec installation. We recommend reaching out to the coach manufacturer, as they may participate in resolving the issue” Neither company appear to be concerned for safety