2020 Forest River Georgetown

The contact owns a 2020 Georgetown Forest River RV built on a 2019 Ford F53 chassis. The contact received notification of NHTSA Campaign Number: 24V103000 (Equipment) however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool showed no open recall.

While driving down [XXX] in Denver the front welds holding the propane tank broke. This left the propane tank at an angle only supported by the rear welds. Was fortunate that another RVer flagged us over and we were able to get off the highway and used a ratchet strap to support it so we were able to drive to get the bracket welded back into place. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While a mobile welder was repairing the cracked rear bracket holding the ASME propane tank (NHTSA complaint #11555667) he repaired another full-depth crack, this one on the actual ASME propane tank mounting flange itself. This flange is welded to the tank by the tank manufacturer. This cracked tank flange is bolted directly to the cracked rear angled mounting bracket reported on Nov. 17, 2023. The tank mounting flange crack was close to an inch long and cracked at a gusset on the rear, outer mount of the tank ("outer" means nearest the propane compartment door). Please see the top and bottom pics. This second crack had rust in it on the top but was only partially rusted on the bottom, as if the crack may still be progressing. See the black spot on the compartment close-up pic. (I did not have any white paint to cover the welded area.) From previous pics I have this second crack is at least six months old and probably older. I just never really noticed it. One way this gusset-reinforced flange could crack is if the metal was repeatedly flexed at the end of the gusset, which is where it cracked. Interestingly, BOTH of these cracks occurred at the rear outer, just 2.5 inches from each other. The motorhome propane tank mounting structure has a unique support design in that only three of the four "corners" are supported by other structure. Normally a horizontal frame member supporting a lot of weight (up to 200 lbs total in this case) has a support at each end to eliminate flexing. The rear horizontal frame in fact is supported on each end by a vertical piece of square steel tubing that is welded to other structure. See the pic. The FRONT of the ASME tank mount has a similar horizontal run of square steel tubing. On the inner section of the welded bracket there is a 45-degree angle iron support welded to steel frame. See the pic. BUT the outer end of the front horizontal steel frame is NOT supported in any way; it's just sticking out. See the pic.

Another owner of a 2020 Forest River Georgetown GT5 model 34H5 just posted a pic of a crack at the 90-degree bend in the rear propane tank mounting bracket. This is an ASME tank that can contain 19.5 actual gallons of propane. Previous ASME propane tank mounting bracket cracks reported by owners of Georgetowns were all on the front propane tank mounting bracket and were broken welds that allowed one end of the propane tank to drop almost to the road while driving. They were NOT a crack at the 90-degree bend in the bracket and also NOT on the rear bracket. I just cut three tie wraps to expose that bend on our 2020 Georgetown GT5 34H5 and my rear propane tank mounting bracket is cracked in exactly the same place. The crack is full depth at the exposed end of the bend. The crack appears to extend 2" to 3" through the bend of the 8" long bracket. There is some rust in the crack at the end so the crack started a while ago. A total failure of the bracket would allow one end or both ends of the ASME tank to fall and strike the ground. That could be like a bomb exploding when driving, the same as the previously reported front ASME tank bracket failures could cause. Our motorhome is four years old with about 17,000 miles. It was built in May 2019.

Two owners of Forest River Georgetown Class A motorhomes, one a 2020 model year and one a 2022 model year, reported on a forum that one of the two brackets holding their 24.5 gallon water capacity ASME propane tank in place had its tack welds break, allowing one end of the tank to drop so far it was visible by passing cars. Both reported they were flagged down by people passing them. (The end of the propane tank likely was bouncing up and down on the remaining bracket.) Both used a strap to hold the tank in place until the bracket could be re-welded. Both reported that the repair shop then installed two bolts through the front and rear bracket to help hold the tank in place if the welds broke again. Neither owner took a picture of the propane tank hanging down so the attached pictures show their brackets after the repair. 24.5 gallons water capacity is about 19.6 actual gallons of propane at 80%. On my motorhome a visual inspection of the affected brackets did not reveal cracked welds but did show that the front bracket on the propane tank itself was installed slightly off and the inner edge of the front tank bracket is against a welded corner of the bracket instead of flat against the front frame bracket. Light is visible in the gap between the tank mounting bracket and the frame mounting bracket. If other tanks are like this it could mean that the upward pressure from tightening the inner tank mounting bolt applied stress to the welded bracket where there should not have been any. (The approximate date of those two failures is unknown however the 2022 model year owner reported they had the repair covered under warranty. I thus selected today's date because the form field has a date as mandatory.) (I had to select Aftermarket Equipment as BAL OTHER because "OTHER" was not allowed. I do not know who installs the propane tank mounting structure. It could either be the final vehicle manufacturer or the third-party upfitter they use for similar work.)

Windshield developed a stress crack starting at the bottom-center, and is growing vertically. Several other owners have reported the same issue, originating in the same exact spot. Some have reported that the original windshield was too large and, consequently, did not leave sufficient room for caulking at the bottom. Others have reported that a defect in the vehicle's dash causes it to press against the windshield. This has been reported to the factory by numerous other owners, and the factory refuses to correct the issue.

The contact owns a 2020 Forest River Georgetown Motorhome built on a 2020 Ford F-53 chassis. The contact received notification of NHTSA campaign number: 21V202000 (Suspension, Power Train) however, the part to do the recall repair was not yet available. The contact called the local dealer who stated the parts were not available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the issue however, no additional assistance was provided. The contact had not experienced a failure. Parts distribution disconnect.

THE SWAY BAR ON MY RV SITTING ON THE FORD F53 CHASSIS BOLTS CAME OUT 3 OF THE 4 AND TORE THE BRAKE LINE IN HALF (POSSIBLY ONLY THE ABS LINE). THIS VEHICLE HAS LESS THAN 4,000 MILES AND I HAVE HAD TO FIX A LOT OF THEIR QUALITY CONTROL ISSUES. THIS COULD HAVE KILLED SOMEONE THOUGH. CONSUMER HAS ATTACHED ADDITIONAL PHOTOS WITH SWAY BAR IS MISSING BOLTS ON EACH SIDE OF MOUNTING BRACKETS, WHICH CAUSED THE SWAY BAR TO PINCH IN HALF OF ABS LINE.