I emailed all of your comments to Rick at Sendel. I'll share his responses in a couple of posts.
On the T03 (Airstream Eddie Bauer) Design:
Bottom line COPIES of our Sendel T03 are being recalled by other vendors - and obviously were not tested to J1204 industry compliance standards for the trailer industry.
The problem is that the re-called wheels look and smell like ours. We have already begun to see warranty challenges. The re-called wheels will not have the Sendel manufactured stamp.
----------------------
This report serves as HiSpec Wheel and Tire, Inc’s notification to the U.S. Department of Transportation, National Highway Traffic Safety Administration that a potential defect related to vehicle safety exists in certain 16” S5 style aluminum recreational and utility trailer wheels. HiSpec Wheel and Tire determined this defect exists in wheels supplied by HiSpec Wheel and Tire from March of 2010 thru January of 2012.
I. Manufacturer, Designated Agent, and Other Chain of Distribution Information Manufacturer’s corporate name: HiSpec Wheel and Tire, Inc. Equipment’s brand or trademark name owner(s) (where applicable): HWT Designated Agent (imported equipment):
HiSpec Wheel and Tire, Inc. 1655 East 12th Street Mishawaka, IN 46544
This notification concerns equipment that was supplied by HiSpec Wheel and Tire to:
Americana Tire and Wheel (ATW) 7095 Americana Parkway Reynoldsburg, OH 43068
and
Badger Trailer Components N174 W21030 Alcan Drive Jackson, WI 53037
Supplier of the 16” S5 Aluminum Trailer wheel:
Country of Origin: China
Manufacturer: MinShianIndustrialCompany
Factory: Shanghai Guoxing Metal Product Co. LTD No. 3888 Pei-Ching Road
Feng Xi Town, Qingpu Country, Shanghai, China 201705
Any Inquiries about this report should be directed to:
HiSpec Wheel and Tire, Inc.
1655 East 12th Street
Mishawaka, IN 46544
Attention: Ron Williams – General Manager Phone: (574) 807-8588
Fax: (574) 807-8596
Manufacturer’s assigned campaign number (where applicable): N/A II. Identification of the Recall Population and Its Size
Type of Equipment: 16“ S5 Style Silver Aluminum Trailer Wheel
Part Number: ATW PN: 22658HWT or HWT PN: S567655
Size: 16 x 6.5J 6 Lug
Inclusive Dates of Manufacture: Casting Dates 01/2010 to 07/2011
Description of the Wheel: Split Spoke 6H Silver Aluminum Trailer Wheel
Total Number of Wheels:
Americana Tire and Wheel: Badger Tire and Wheel:
Total:
172 wheels 22 wheels 194 wheels
Type of Equipment: 16“ S5 Style Silver Aluminum Trailer Wheel
Part Number: ATW PN: 22659HWT or HWT PN: S567865
Size: 16 x 6.5J 8 Lug
Inclusive Dates of Manufacture: Casting Dates 03/2010 to 03/2011
Description of the Wheel: Split Spoke 8H Silver Aluminum Trailer Wheel
Total Number of Wheels:
Americana Tire and Wheel: Badger Tire and Wheel:
Total:
337 wheels 0 wheels 337 wheels
Type of Equipment: 16“ S5 Style Black Aluminum Trailer Wheel
Part Number: ATW PN: 22659HWTB or HWT PN: S567865B Size: 16 x 6.5J 8 Lug
Inclusive Dates of Manufacture: Casting Dates 03/2010 to 03/2011 Description of the Wheel: Split Spoke 8H Black Aluminum Trailer Wheel Total Number of Wheels:
Americana Tire and Wheel: 68 wheels
Badger Tire and Wheel: 0 wheels Total: 68 wheels
Type of Equipment: 16“ S5 Style Silver Heavy Duty Aluminum Trailer Wheel Part Number: ATW PN: 22660HWT or HWT PN: S567865HD
Size: 16 x 6.5J 8 Lug
Inclusive Dates of Manufacture: Casting Dates 03/2010 to 03/2011 Description of the Wheel: Split Spoke 8H Silver Aluminum Trailer Wheel Total Number of Wheels:
Americana Tire and Wheel: Badger Tire and Wheel:
Total:
231wheels 12 wheels 243 wheels
Type of Equipment: Aluminum 16“ S5 Style Black Heavy Duty Aluminum Trailer Wheel
Part Number: ATW PN: 22660HWTB or HWT PN: S567865HDB Size: 16 x 6.5J 8 Lug
Inclusive Dates of Manufacture: Casting Dates 03/2010 to 03/2011 Description of the Wheel: Split Spoke 8H Black Aluminum Trailer Wheel Total Number of Wheels:
Americana Tire and Wheel: Badger Tire and Wheel:
Total:
4 wheels 0 wheels 4 wheels
Grand total number of items of equipment in the recall population: 846 Wheels
The percentage of the recall population estimated to contain the defect or noncompliance: 50%
Identify and describe how the recall population was determined (e.g., on what basis the recalled models were selected and how the inclusive dates of manufacture were determined):
The 16” S5 style wheel was a new design for HiSpec and required new tools. The first production run of this wheel was in January of 2010 and since the volumes were relatively low, only one mold was developed for both the 6 lug and 8 lug variants. From the first casting run in January 2010 to the last casting run in July of 2011, only one mold has been used. As a result, any issues directly related to the mold would apply to all variants using that same mold. Even though there are no known issues related to the 6 lug variants, they are also suspect since they used the same mold as the 8 lug variants. The above quantities are based on the entire production of the 16” S5 wheel minus the wheels that have been returned to HiSpec. These quantities are assumed to be in the field and can be at the trailer manufacturer, on the dealer’s lots, or in the hands of end users.
Describe how the recall population is different from any similar items of equipment not subject to this notification:
Each different style and size of cast aluminum wheel is produced using a unique mold. As a result, any defects directly related to mold design (such as shrinkage porosity) will propagate throughout the entire population using that mold. The defect in the 16” S5 wheels has been found to be directly related to the mold so only wheels produced in this mold are suspect. No other HiSpec wheels uses these molds so they are unaffected by this issue.
III. Description of the Defect or Noncompliance and Chronology of Events
Describe the defect, including a summary and detailed description of the nature and physical location (if appropriate) of the defect or noncompliance. Graphic aids should be provided where necessary.
A crack can develop in the spoke of the wheel which can lead to additional cracks and potential failure over time if the wheel is not removed from service. Below is an example of one out of a total of 6 field returns. The cracks shown below are typical.
Cracked Spokes
Describe the cause(s) of the defect or noncompliance condition.
Fracture of the spokes is due to porosity that occurred in the manufacturing process. This porosity results in voids in the castings which reduces the load carrying capacity of the wheel. Since the spokes are the load path from the road to the trailer they experience higher stress levels than the other elements of the wheel and are more sensitive to porosity. Porosity in aluminum castings is always present, however in this case the porosity levels on the known defective wheels exceeded the allowable levels. It was this higher level of porosity in the spokes that resulted in the fractures. Below is an X-ray image of one of the wheels.
Spoke Porosity
Describe the consequence(s) of the defect or noncompliance condition.
If the wheel is not removed from service and the crack is allowed to propagate through all the spokes, the tire and wheel can separate from the trailer resulting in a potential safety hazard.
Identify any warning(s) that may precede the defect or noncompliance condition.
Wheels initially crack in one spoke and the crack will then propagate to the adjacent spokes. Early detection of cracks in one or more of the spokes can minimize the potential hazard.
For defects, provide a dated, chronological summary of all the principle events that were the basis for the determination that the defect is related to motor vehicle safety, including a summary of all warranty claims, field or service reports, and other information such as numbers of crashes, injuries and fatalities.
Date
9/29/2011 10/9/2011 12/14/2011
Event
First S567865 wheel returned to HiSpec from ATW-Elkhart.
Casting Date Code: 3/2010
Returned wheel sent to manufacturing location in China for evaluation
Report issued indicating no dimensional issues or problems with mechanical properties. Three S567865 wheels returned to HiSpec from ATW-Elkhart.
Casting Date Code: 3/2010
It was noted that these 3 returned wheels came from the same customer as the original wheel received on 9/29/2011.
12/15/2011 12/16/2011
1/6/2012 1/9/2012
1/17/2012 1/18/2012
1/23/2012 1/25/2012 1/25/2012
1/25/2012 1/31/2012
2/1/2012 2/2/2012
2/10/2012
End Use customer identified – triple axle car hauler with rubber torsion axles which is known to be a worst case application under certain conditions.
Wheels (2) from inventory with the same casting date code (3/2010) sent to outside laboratory for durability testing per SAE J1204 – 1 wheel for radial fatigue and 1 wheel for cornering fatigue testing.
Radial Fatigue Test Results – test sample with 3/2010 casting date code did not meet the test specification.
Cornering Fatigue Test Results – test sample with 3/2010 casting date code completes testing – meets test specification
Testing resumes on the same wheel to 2 x life
Test sample successfully completes testing to 2x life
Cornering fatigue testing on this sample ends.
ATW informed of durability concern on the 16” S5 8 lug variants.
HiSpec requests return of all unused 16” S5 8 lug inventory.
ATW – Georgia notifies HiSpec that two S5 16” 8 lug wheels have been returned with cracked spokes. Both wheels came from the same customer – no additional details regarding the customer available.
Cracked field return received on 12/14/2011 sent to outside lab for X-ray.
Results from field return indicated porosity in the spokes.
Field returns from ATW-Georgia arrive – 2 wheels
Casting Date Code: 3/2010
Unused inventory arrives from ATW-Georgia.
Field returns from ATW-Georgia and 48 samples taken from inventory sent for X-ray evaluation.
Results on 2 field returns from ATW-Georgia showed porosity coincident with the cracks in the spokes.
X-ray evaluation completed on the 48 inventory samples. Results indicate porosity in the spokes which is unusually consistent. The consistency of the porosity is indicative of mold cooling issues which would affect all wheels cast using that mold.
Based on these findings, the S5 16” 6 lug variant was added to the list of suspect wheels to be voluntarily recalled.
Request sent to ATW requesting return of un-used S5 16” inventory to HiSpec.
Last shipment of unused S5 16” inventory from ATW-Elkhart arrives at HiSpec.
Warranty Claims A total of 6 S567865 wheels have been returned to HiSpec.
Safety Incidents
HiSpec is unaware of any injuries or crashes associated with the use of this wheel.
IV. The Remedy Program and Its Schedule
Describe the program for remedying the defect or noncompliance, including the plan for reimbursing those owners and purchasers who may have incurred costs to remedy the defect or noncompliance before receiving the manufacturer’s notification concerning that defect or noncompliance. Also include, where applicable, details with dates concerning any production remedy that was conducted or will be conducted.
1. Hispec will issue a letter to ATW and Badger Trailer Components describing the defect, the potential hazard, the inspection process and the available replacement wheels.
2. ATW and Badger will notify their customers (mostly OEs) that purchased the wheels and request a list of VIN #s and customers (dealers) that purchased the wheels.
3. The dealers will then provide a list to HiSpec which includes the VIN# and end user information including address and phone number if possible. Hispec will generate and maintain this data base.
4. The dealers and end users will contact HiSpec directly with their VIN # and information and receive an authorization code to get the wheels replaced at no cost.
5. HiSpec will ship the replacement wheels (different style) immediately, including call tags to return the wheels involved in the recall to HiSpec.
6. HiSpec will monitor returned wheels using the data base developed in step 3.
7. HiSpec will generate provide quarterly status reports to NHTSA and assist the efforts of the OEs, and dealers.
Provide the estimated date(s) on which owner and purchaser notifications will be issued and the estimated date(s) for completion of those notifications.
Owner and Purchaser notifications are planned to start by February 24 and be complete by March 16, 2012.
Provide the estimated date(s) on which dealer and distributor notifications will be issued and the estimated date(s) for completion of those notifications.
Dealer and Distributor Notifications planned to start immediately and be complete by February 29, 2012
Describe the distinguishing characteristics of the remedy component/assembly versus the recalled component/assembly.
The replacement wheels will be a different style as shown below.
Alternatively, if the customer choses to wait for new wheels in the same style, the HiSpec Logo will be changed, both on the front of the wheel and cast into the back of the wheel.
Current Logo New Logo
*************IMPORTANT REMINDERS**************
A DRAFT version of the letter that the manufacturer intends to mail to owners and purchasers notifying them of the defect and/or noncompliance must be submitted to NHTSA at least five Federal Government business days before those letters are issued. In addition, it is recommended that the draft version of the letter that the manufacturer intends to send to its dealers and distributors concerning the defect and/or noncompliance also be submitted for review. For prompt receipt and review, drafts may be submitted to the attention of the Recall Management Division (NVS-215) via facsimile on
(202) 366-7882, or email to
RMD.ODI@dot.gov.
A representative copy of all notices, bulletins, and other communications that relate directly to the defect or noncompliance and which are sent to more than one manufacturer, distributor, dealer, or purchaser, must be submitted to NHTSA no later than five days after they are initially sent. This requirement applies both to the final version of the notification letter that is sent to owners and purchasers, as well as the final version that is sent to dealers and distributors. It also includes any follow-up notifications issued concerning a recall. The representative copies of the letters sent to owners and purchasers, and dealers and distributors, must be submitted via certified mail. It is strongly recommended, however, that additional representative copies be submitted via facsimile on
(202) 366-7882, or email to
RMD.ODI@dot.gov, so that the submission can be more promptly reviewed. All submissions should be conspicuously labeled with the appropriate NHTSA-assigned recall number.
Linear Mode
