LCI RV Entry Step Failures

What NHTSA investigated

The Office of Defects Investigation (ODI) opened this investigation based on four Vehicle Owner Questionnaires (VOQ).The VOQs report failures of the motorized entry steps used on some recreational vehicles.When extended the steps reach out and down from the vehicle.In the retracted position the step platforms are stacked on top of each other in a compact package under the vehicle body.The gear used to actuate the steps can separate from the actuation motor allowing the steps to unintentionally extend or retract in an uncontrolled fashion.ODI was aware of one injury event prior to opening the investigation. An additional four injuries were reported to Lippert Controls Inc. (LCI) during the investigation.An Information Request Letter (IR) was sent to LCI in order to gather detailed information about the alleged defect. ODI analyzed the IR response data, simulated the failure on an exemplar set of stairs, and inspected broken parts.Complaint and warranty data indicated that the alleged defect was occurring at a significant rate.Constructing a test stand and recreating the failure mode clearly demonstrated the safety consequence of a separated drive gear.Extended steps with a separated drive gear retract when a vertical force is applied to the step.This retraction can capture an individual's foot or ankle as they ascend or descend the steps. Such an action can cause the individual to fall more than three feet to the ground.After analyzing the failure mode, the Vehicle Research and Test Center (VRTC) suggested that the center drive gear bolt appeared to fail from a bending moment.Several conditions might contribute to this type of failure.LCI reported no design changes during the production of the subject components including the drive gear bolt.Through testing, LCI attempted to determine the root cause of the gear bolt failures, but voluntarily recalled the subject components prior to completing this testing and making this determination.This investigation is closed because recall 15E-007 addresses the alleged safety defect.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following complaint identification numbers:10537821, 10605447, 10684011, 10684277

Recalls that followed

1. Haulmark — Equipment: Recreational Vehicle/Trailer16V1320004 March 2016217 vehicles
2. Showhauler — Equipment: Recreational Vehicle/Trailer16V03900026 January 2016190 vehicles
3. Newmar — Equipment: Recreational Vehicle/Trailer16V00800013 January 20163,712 vehicles
4. Gulf Stream — Equipment: Recreational Vehicle/Trailer16V00700011 January 2016662 vehicles
5. Foretravel — Equipment: Recreational Vehicle/Trailer16V0030005 January 201623 vehicles
6. Tiffin — Equipment: Recreational Vehicle/Trailer15V88000028 December 201514,889 vehicles
7. Holiday Rambler — Equipment: Recreational Vehicle/Trailer15V87200023 December 20152,123 vehicles
8. Forest River — Equipment: Recreational Vehicle/Trailer15V79800025 November 20159,687 vehicles
9. Thor Motor Coach — Equipment: Recreational Vehicle/Trailer15V74500010 November 201512,656 vehicles
10. Lippert — Equipment: Recreational Vehicle/Trailer15E07800024 September 201547,340 vehicles

Vehicles covered

Source

From NHTSA’s investigation file, rebuilt daily. To report a problem with your own vehicle, go to nhtsa.gov/report-a-safety-problem. All open investigations.