NEWMAR Complaints

On Jan 2, 2021, I filed NHTSA complaint #11386115. To date I have heard nothing other than an acknowledgement of receipt of the complaint. I would like to point out that this problem is on-going, increasing in severity and number of occurrences, and can easily be considered a life safety issue. As I’m sure you are aware, vehicles conveying human beings are becoming randomly and unpredictability stranded due to faulty sensors on otherwise properly functioning emission systems. This problem is easily resolvable with a simple policy modification, but because it involves emissions, and by extension theoretically the environment (although in this case this is not accurate), there is no apparent willingness to address the problem. While I’m sure you have had many complaints, you are probably hearing from a very small percentage of the people actually affected by this issue. However a simple google search will literally reveal many thousands of instances of people becoming stranded and finding themselves unable to acquire the parts necessary to effect repairs due shortages resulting from the enormity of this issue. While a solution at the policy level may be an unpopular concept I would like to direct your attention to this forum https://www.irv2.com/forums/f258/def-sensors-complaint-filed-with-nhtsa-518276-6.html#post5824588, and specifically this excerpt from the most recent post: “....a simple firmware update would work. It’s just a matter of willingness. Maybe a few folks have to die as a result of a derate first.“ I hope that this complaint is elevated to the decision maker level and that it is taken seriously. At this point your organization is on notice that a life safety issue exists with no apparent effort or willingness to address the problem. If nothing is done to correct the problem, your organization will by omission, be responsible for any tragedy resulting from the issue. Thank you for your consideration.

These vehicles, built on a Spartan K3 chassis and powered by a Cummins ISX-12 engine are experiencing very high failure rates in the DEF system control head. When the control head fails, it sends error codes that result in derating engine power dramatically and/or immediate engine shut-down. This creates a very dangerous situation for anyone driving a motorhome that experiences this problem. In extreme cases, it may stop the vehicle in traffic lanes. Spartan Chassis says replacement DEF control heads are in extremely short supply and they will not provide one to a repair facility unless the affected vehicle has experienced a full derating; an initial warning message of a failing control head is deemed insufficient cause for them to provide a replacement part. Their official response is that “you must drive it until it fails before we will provide a replacement unit.” This means drivers of these motorhomes will either be subject to sudden (and, potentially very dangerous) engine shut-down, or they must cease using their expensive motorhome until such time as Spartan Chassis feels they again have a sufficient stock of replacement units. Many motorhome owners use their vehicles full time; they are their home. The inability to safely use them places a huge burden on those owners. I believe NHTSA needs to issue a recall on affected vehicles and direct Spartan Chassis to implement a software emergency bypass of the engine derating caused by a faulty DEF control head. It is my understanding that this software bypass solution already exists and is currently implemented on emergency vehicles (fire trucks) produced by Spartan Chassis.

The mounting brackets for the rear axel sway bar was missing a bolt in each bracket. Passenger side bracket was hanging below sway bar, driver's side had top bolt missing and was loose. Talked to Ford tech and was told to install a grade 8 bolt with a lock washer and nut. These bolts are M16s, grade 10.9, can I replace them with 5/8 inch grade 8 bolts?

Shortly after departing from J&J RV Park in Hot Springs, Arkansas, in my vehicle, a motorhome, two yellow check-engine lights illuminated on the dashboard. I continued driving for 52 miles to my next destination, Downtown Riverside RV Park in North Little Rock, Arkansas. The engine ran normally, and I arrived safely. I checked the vehicle's computer system on the dashboard and located three trouble codes: 3364, 1761, and 3031. I contacted the vehicle's chassis manufacturer, Spartan Chassis in Charlotte, Michigan, and was told the codes indicated the vehicle's Diesel Exhaust Fluid (DEF) head was defective and needed to be replaced. The gentleman told me not to drive the motorhome and to remain in a safe haven off the road, which in my case is the RV park. He said the limited number of DEF heads in Spartan's inventory are being held for customers whose engines have displayed red stop-engine lights, gone into limp mode and stranded the customers on the side of a road. Those customers receive a new DEF head by overnight mail, are back on the road within a couple days and are able to continue their normal travels. The limited inventory does not allow for customers like me who are not broken down somewhere to receive the DEF head quickly. Spartan's inventory is not anticipated to be replenished until sometime in August 2021. Therefore, if I choose to follow Spartan's recommendation, which I plan to do, I have to cancel campground reservations and summer travel plans and stay in place for at least two months. I'm on a waiting list to receive the part. This is a well-known, long-term problem on motorhomes manufactured by Spartan and other companies, and is supposedly affecting the trucking industry. It has been much discussed on online forums. Spartan's DEF head is produced by Shaw Development LLC in Bonita Springs, Florida. The problem has not been confirmed by a local dealer or independent service center. The vehicle is available for inspection.

2021 NEWMAR BAYSTAR W/ FORD F53 CHASSIS. ABS & TRACTION CONTROL (ADVANCETRAC) LIGHTS CAME ON 10 MINUTES AFTER WE TOOK DELIVERY OF RV. 32 DAYS IN FORD SERVICE DEPT. REPLACED ABS SENSOR. REPLACED ECBM. PERFORMED WIRING HARNESS OVERLAY (FIRST PARTIAL, THEN COMPLETE). REPLACED O-RING + WHEEL HUB + BRAKE ROTOR ASSEMBLY. WARNING LIGHTS WENT OUT, BUT CAME ON AGAIN ABOUT 250 MILES LATER. CRUISE CONTROL & HILL ASSIST DISABLED. 11 DAYS IN 2ND FORD SERVICE DEPT. REMOVED & REPLACED ENTIRE WIRING HARNESS OVERLAY. WARNING LIGHTS WENT OUT. NOT SURE FOR HOW LONG. WAS TOLD FORD MAKES THE WIRING HARNESS AS PART OF CHASSIS BUT NEWMAR MODIFIES IT WHEN COACH PUT ON.

Diesel Exhaust Fluid Control unit failed 04/28/21 @ 21,151 miles. Unfortunately this can cause the motor to de-rate with speed restricted to 5mph. Very dangerous on the freeway. Problem was confirmed by the Cummins codes generated and verified by both Spartan motors as well as the repair facility that performed the repair. No warning lamps, symptoms, or messages prior to the failure.

On 5/23 I started getting a code "SPN3031 FMI9" which says the DEF temperature is rising too fast, no other codes were present in the fault list (the engine was running at the time I grabbed the fault list). Only the engine outline icon was lit. I had only driven 3 miles from my house to fill up the RV with fuel. I turned the engine off and restarted, getting the same code. After driving back home I pulled up the list again and it was the same. On 5/25 I contacted the local repair shop and they took my information. They called back on 5/26 saying that Spartan (chassis manufacturer) thought I should have more codes. Early on 5/27 I pulled the fault list from the RV with the key in accessory position and I got 2 fault codes, the SPN3031 and also a "SPN1761 FMI9" but it also showed different icons than the prior query, also showing the "check engine" and "Regen" lights. Since I had seen 2 different fault sets I decided to remove the key and try again. I only got the single engine outline icon and the SPN3031 code. I didn't receive the SPN1761. I provided this information to the repair shop shortly after they opened and about an hour later I got a call back from Spartan. They indicated that I would need a new DEF head, the one I had was failing and it was a very common problem this year such that they had none in stock. They also said they weren't sure when they could get me a new one or how many miles the RV could be driven before it would start to derate it's power. I fully support the DEF improvement in air quality, but it is not safe to have a vehicle that is going to start derating power potentially leaving it useless and no ability to get the warranty replacement parts quickly. Manufacturers should have to supply parts for warranty claims before they can sell new items when there is a shortage. The consumer shouldn't be left with an inoperable vehicle while they sell the limited supply to new consumers for a profit.

The seats that are installed on the front passenger side have I’ll positioned seatbelts. There is no adjustment for it. I’ve reported it to the dealership and they said they hear it all the time but there is nothing they can do. The seatbelt crosses the chest such that the seatbelt anchors at the top of the seat crossing the neck. Should an accident occur, the seatbelt will be across the neck. This could result in a devastating injury. If I were short, I could understand the positioning but I am 5’8”. I took photos and are attached.

RV WENT INTO 5MPH DERATE DUE TO DEF HEADER MALFUNCTION. I WAS VERY LUCKY TO BE IN AN RV PARK, HOWEVER THERE IS NO WAY TO REPLACE THE DEF HEADER WITHOUT RAISING THE RV (DUE TO THE LOCATION OF THE TANK), SO IT COULDN'T BE REPLACED THERE. I HAD AN APPOINTMENT TO REPLACE THE DEF HEADER AT FREIGHTLINER OF HOUSTON, DUE TO THE WARNING LIGHTS. HOWEVER WHEN I STARTED TO DRIVE THERE FOR THE APPOINTMENT, I FOUND THE RV WOULD NOT GO OVER 5MPH. SINCE THE DEALER WAS 60 MILES AWAY (AND IT WAS THE NEAREST ONE), THERE WAS NO WAY I COULD MAKE IT.

NEW NEWMAR BAY STAR 2021 ON A 2020 FORD F53 CHASSIS. ON OUR FIRST TRIP WE NOTICED BRAKE NOISES. WE TOOK IT TO A FORD SERVICE CENTER AND THEY REPORTED BOTH FRONT BRAKE PADS WERE CRACKED AND THE ROTORS DAMAGED. THIS IS A BRAND NEW RV!