27 of the
210 complaints filed about the Newmar Dutch Star
are about the engine —
13% of everything owners reported.
The worst model year for it is 2018.
The Freightliner chassis under this motorhome uses a Power Distribution Module (PDM) that is a fuse panel "block" that powers several coach items, from taillights, brake lights, engine cooling, air conditioning and several other components. The PDM intermittently fails as it can't support the amount of power it must distribute without overheating and shutting off several components as you drive. Especially dangerous is the lost of rear brake and taillights. The PDM was recalled by Freightliner and was replaced with the same item. I'm only guessing that they thought they had a bad batch and replacing it with another would solve the issue. The replacements failed and they recalled the product again. This time, they left the failed PDM in place and removed several circuits from the unit and ran them outside of the PDM with their own fuses. Again, I think the idea was to reduce how much amperage the unit had to handle. This bypass repair is still failing on some coaches, and Freightliner is refusing to cover the repair under the initial recall.
NHTSA complaint #11620605 — an unverified report by a vehicle owner.
My DEF sensor failed which required towing on Interstate 80 in a highly congested area. This same failure has happened to many other motorhomes and trucks. It creates a very unsafe situation which needs to be corrected. Please require the manufacturer to correct the flaw and recall all in use. Thank you.
NHTSA complaint #11521780 — an unverified report by a vehicle owner.
I was driving home this weekend in my motorhome and noticed smoke coming out of rear of vehicle. I thought we were on fire. Fortunately I was able to get off the road and no injuries occurred. However, there will be many injuries if this problem is not recalled. The vehicle has a Cummins ISL Diesel motor. Vehicle has 33K miles. The #1 fuel injector line fails. If you look online this has happened many of times. Cummins also has a TSB for failure. Also, the "revised" part comes with a new bracket to prevent future failure. So Cummins is aware of problem. The fuel is spraying all over the engine compartment and straight on the exhaust. This is dangerous and people will die, or at the very least cause extensive damage. I tried to reach out to Cummins and received no response. Thanks for your time.
NHTSA complaint #11435626 — an unverified report by a vehicle owner.
The contact owns a 2019 Newmar Dutch Star Spartan Motor Chassis RV. The contact stated while driving 45 mph, there were several unknown warning lights illuminated. The RV was driven to the dealer to be diagnosed. The contact was informed of the DEF head (Diesel Exhaust Fluid) failure. The dealer was able to clear the error code but stated that the failure recurred, and the engine degraded the speed on the RV. The mechanic recommended that the RV not be driven. The RV was not repaired. The manufacturer was made aware of the failure. The failure mileage was 5,409.
NHTSA complaint #11426115 — an unverified report by a vehicle owner.
The Shaw DEF head failed. Started engine and received MIL light - Emissions. Checked codes and saw "SPN 3031 FMI 9-Abnorm. Update Rate" - "Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature". It should be noted that the motorhome was in my enclosed shop, no excessive temperature. It was started in the morning after setting overnight. Knowing that this could potentially derate engine, I contacted Spartan & a local repair facility. Was able to get DEF Head replaced. I am the original owner of the motorhome. Fortunately this happened while preparing for 3-week trip (at home) and not on road.
NHTSA complaint #11425564 — an unverified report by a vehicle owner.
We got the check engine light on after starting up our coach on July 6. We got several fault codes: SPN 3364 FMI 9, SPN 1761 FMI 9, SPN 3031 FMI 9. The codes indicated that we had a faulty DEF Header and it needed to be replaced. And if we drove the coach at some point it would "derate" to 5 miles an hour and we would not be able to drive it. We were told by the chassis maker (Spartan) that we would likely not be able to get a replacement part until September or October due to the global microchip shortage. And even though there was nothing actually wrong with engine or the DEF (we had a full tank) there was no work around. Because we were in West Yellowstone where there was no diesel engine service nor a place we could leave the coach for several months. We decided to drive the coach to our next destination, Lander Wyoming which had two Cummins engine shops. We made it there, but then got the "stop engine" code - SPN 5246 FMI 16. The coach derated and we could no longer drive it. The Cummins service shop was able to clear the "stop engine" code, so we could drive it. But the check engine codes would remain until the DEF header was replaced. And countdown would restart to "stop engine". On the irv2.com RV blog forum, Spartan chassis owners, with Shaw DEF headers have reported the DEF header failure. A number have had multiple failures. Since it seems as though it may be months before a supply of DEF headers will be readily available and there is nothing fundamentally wrong with the engine, it would be tremendously helpful for Cummins or Spartan to design a workaround while the parts supply is rebuilt and it seems likely that Shaw needs to redesign their DEF Header to reduce the failure rate or Spartan needs to find a new supplier.
NHTSA complaint #11425312 — an unverified report by a vehicle owner.
Since purchasing this RV new, I have had the DEF Head fail twice. 1st time was Sep 2019 with a mileage of 14066 and the 2nd time was April 2021 with a mileage of 16018. Both times DEF Header Assemblies were replaced. When these fail the motor can de-rate at any time. Very dangerous when traveling down the highway. Both times the low DEF warning and check engine lights came on.
NHTSA complaint #11425316 — an unverified report by a vehicle owner.
When preparing to leave, my coach received a check engine light, and 3 error codes from the Cumins ECU. SPN 3364, 1761 and 3031. All FMI code 9. My engine is Likely now debated to 5% power and I was just able to return it to the driveway at the house. Thankfully I hadn’t gotten onto the busy interstate when it happened. After contacting Spartan Chassis, they informed me that I needed a new DEF Head unit. This has been a major issue across the industry. The part is manufactured by SHAW and parts are not available. I was told by Spartan “August or September” for parts. I am unable to move the coach for fear that it is in fact debated to 5% so will need to have a mobile mechanic dispatched to replace. I understand the need for emission controls, but to derate the engine because we might have a little bit dirtier tailpipe until its fixed…. Major safety issue as there is NO workaround.
NHTSA complaint #11425348 — an unverified report by a vehicle owner.
The failure has occurred in the emission system. The DEF SENSOR set off 2 Check Engine light warnings on the dash. It did not tell me any other information. I was fortunate to return from my trip without incident. However, after speaking with the chassis manufacturer (Spartan), I was fortunate to be able to continue. Had I gone any further the engine would have begun a shutdown leaving my 24 ton RV stranded roadside. It could have been very serious breakdown on a metro highway causing major traffic jams or left stranded in a remote location. The component required for replacement is not available till late Aug or Sept. As we live full time in the RV we are now stranded unable to travel until the part is available. Although our example appears to be an inconvenience we have dozens of other RVers experiencing this same problem and unaware of being stranded until the failure occurs. Whatever is causing the failure of these DEF sensors, owners should be notified and a general recall for replacement should be issued.
NHTSA complaint #11425265 — an unverified report by a vehicle owner.
I recently purchased a 2021 Newmar Dutchstar Motorhome, and took delivery recently. The Diesel Exhaust Fluid (DEF) sensor failed in less than 3,000 miles. As a newbie in the motorhome world, I was stunned and very disappointed that this failure occurred so quickly, and also with the ramifications of the failure. When DEF sensors fail the engine can go into derate state which can cause my coach to move at a maximum of 5 mph in less than a couple hundred miles, and then the engine SHUTS DOWN. I contacted Spartan motors, the manufacturer of my chassis, and was told that this is a known problem with diesel engines, and that there is a worldwide problem with the DEF failures compounded by a worldwide shortage in functioning replacement parts. The DEF sensors regulation was passed by EPA in 2016, stating the DEF concentration be measured in the DEF tanks of vehicles. I believe that Shaw Development is currently at the sixth generation of the DEF sensor which are still failing regularly on brand new 2021 motorhomes. That is six attempts to make a part that continues to leave people on long trips stranded. As a female driving my coach, this is a major problem. First, because I cannot even drive my brand-new coach anywhere but also because the prospect of getting stranded on the side of the road, as a female, is too frightening to risk. And there is no prediction when I will get the part needed to repair the failure, or whether that part will be defective too.
NHTSA complaint #11424982 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11421702 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11419516 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11415723 — an unverified report by a vehicle owner.
CHECK ENGINE LIGHT CAME ON, CONTACTED CUMMINS WITH CODE. I WAS TOLD THE DEF HEAD NEEDED TO BE REPLACED. MOTORHOME HAD 5211 MILES. MADE AN APPOINTMENT AND HAD HEAD REPLACED
NHTSA complaint #11386835 — an unverified report by a vehicle owner.
WHILE DRIVING MOTORHOME GOT FLASHING CHECK ENGINE LIGHT AND DEF WARNING MESSAGE. STOPPED VEHICLE AND CALLED SPARTAN (THE CHASSIS MANUFACTURE) WAS TOLD TO NOT DRIVE VEHICLE AS THE DEF HEAD HAD FAILED AND A REPLACEMENT WAS NEEDED. SCHEDULED REPLACEMENT WORK. VEHICLE HAD 3,000 MILES ON IT WHEN THIS HAPPENED. I WAS TOLD THAT THE VEHICLE WOULD BE LIMITED TO 5MPH IS I ATTEMPT TO DRIVE IT FURTHER.
NHTSA complaint #11362911 — an unverified report by a vehicle owner.
DEF SYSTEM FOR DIESEL ENGINE STARTED TO FAIL CAUSING REDUCTION IN PERFORMANCE OF MOTOR HOME. IF I HAD NOT BEEN ABLE TO GET DIRECTLY TO A FREIGHTLINER SERVICE CENTER, I WOULD HAVE ENDED UP ON THE INTERSTATE ABLE TO GO ONLY FIVE MILES PER HOUR AND NEEDING TO BE TOWED. THIS IS AN ON GOING KNOWN PROBLEM WITH THESE ENGINES MANUFACTURED BY CUMMINS. THIS PARTICULAR PART IS FAILING ON A REGULAR BASIS ACROSS MANY CHASSIS MAKERS CAUSING A POTENTIAL DANGER TO THE OWNERS OF THESE COACHES. THE PARTICULAR PART IS CALLED A DEF HEAD THAT REGULATES AND METERS THE POLLUTION REDUCING DEF FLUID. THIS PART NEEDS TO BE IMPROVED AND IF IT DOES FAIL, A BETTER SOLUTION NEEDS TO BE IMPLEMENTED THAT DOES NOT DERATE THE ENGINE PERFORMANCE TO THE POINT OF BEING DISABLED LEAVING PEOPLE STRANDED.
NHTSA complaint #11354474 — an unverified report by a vehicle owner.
WE HAVE HAD TWO DIESEL EXHAUST FLUID (DEF) HEAD FAILURES THAT HAVE REQUIRED REPLACEMENT OF THE DEF HEAD UNIT. THE FIRST SITUATION RESULTED IN A DERATING OF THE ENGINE, LIMITING OUR SPEED TO 4 OR 5 MPH WHILE ON THE INTERSTATE. THE VEHICLE HAD TO BE TOWED 200 MILES TO A SERVICE CENTER, THEN IT TOOK A WEEK TO OBTAIN REPLACEMENT PARTS. THE SECOND SITUATION HAPPENED WITHIN 5 MILES OF A SERVICE CENTER AND WE WERE FORTUNATE ENOUGH TO BE ABLE TO MAKE IT TO THE SERVICE CENTER. HOWEVER, WE ARE SEEING HUNDREDS OF SIMILAR SITUATIONS BEING POSTED TO RV FORUMS ON VARIOUS SOCIAL NETWORKS. A RECALL NEEDS TO BE MADE FOR ALL CUMMINS ENGINES THAT HAVE DEF SYSTEMS. AS PART OF THE SOLUTION, THE DESIGNS NEED TO BE CHANGED SO THAT THE ENGINES CAN CONTINUE TO RUN WITH THE DEF ERROR CODE RATHER THAN SENDING THE ENGINE INTO A DERATE SITUATION AS THIS PRESENTS A SEVERE HAZARD TO OCCUPANTS IN THE VEHICLE, AS WELL AS OTHER TRAFFIC ON THE ROAD. RV BUILT ON A PREVOST CHASSIS ALLOW NORMAL OPERATION OF THE ENGINE AND RV SPEED EVEN WITH THE DEF ERROR CODES.
NHTSA complaint #11354123 — an unverified report by a vehicle owner.
WHILE DRIVING, THE CHECK ENGINE LIGHT CAME ON. MOMENTS LATER, ANOTHER CHECK ENGINE LIGHT CAME ON AND THE DEF GAUGE WENT FROM F TO E AND TURNED RED WITH AN ALARM. WE WERE ABOUT 5 MILES FROM OUR DESTINATION. I CALLED NEWMAR WHO PUT SPARTAN ON THE PHONE. IT WAS THE DEF SENSOR. I WAS ASKED TO DRIVE ONE HOUR AWAY ON A TWO LANE ROAD TO A DEALER. I REFUSED. WE EXTENDED OUR STAY BY ONE WEEK UNTIL THE PART CAME IN (BACK ORDERED). MOBILE TECHNICIANS CAME AND INSTALLED THE PART. I ASKED IF I SHOULD HAVE A SPARE SENSOR... JUST IN CASE...AND WAS TOLD NO. THE.CHECK ENGINE LIGHT WENT OUT AND IT APPEARS TO BE FIXED.
NHTSA complaint #11354120 — an unverified report by a vehicle owner.
WHILE ON A DOWNGRADE WITH THE ENGINE BRAKE ENGAGED AND IN 4TH GEAR, AT ABOUT 1900 RPM, THE SIDE MOUNTED FAN EXPLODED SENDING PLASTIC AND METAL PARTS OUT THE REAR OF THE MOTORHOME SHOWERING THE VEHICLE BEING TOWED AND ANOTHER VEHICLE FOLLOWING BEHIND. UPON INSPECTION THE FAN, WHICH IS DRIVEN BY A HYDRAULIC PUMP, WAS SUPPOSED TO BE ATTACHED BY TWO BOLTS TO A CROSS BAR BETWEEN THE RADIATOR AND THE ENGINE. THE BOLT HOLES IN THE HYDRAULIC PUMP WERE ELONGATED AND BOTH BOLTS HAD SHEARED OFF ALLOWING THE PUMP TO FALL DOWN WHICH RESULTED IN THE FAN BLADES HITTING THE CHASSIS FRAME AND CAUSING THE FAN TO BOUNCE AROUND THE COMPARTMENT HITTING THE RADIATOR AND PIPING AND THE INTERCOOLER PIPING. THIS HYDRAULIC SYSTEM IS ALSO PART OF THE POWER STEERING SYSTEM. UPON BEING TOWED BACK TO RAPID CITY, SD THERE WAS ANOTHER DUTCHSTAR (A 2000) AT THE FREIGHTLINER DEALER WITH THE SAME FAILURE. REPLACEMENT PARTS CONSISTED OF A HYDRAULIC DRIVE MOTOR, RADIATOR AND INTERCOOLER PLUS ALL THE REPLACEMENT FLUIDS FOR BOTH. I RETAINED THE HYDRAULIC DRIVE MOTOR IF NEEDED. IF THE FAN HAD SEVERED THE HYDRAULIC LINE THAT WOULD HAVE DISABLED THE STEERING SYSTEM WITH LOSS OF THE ABILITY TO STEER. ALSO IF THERE WERE NOT A VEHICLE BEING TOWED THAT TOOK THE BLOW OF MOST OF THE PARTS COMING OFF THE ENGINE THE VEHICLE BEING DRIVEN AND FOLLOWING BEHIND COULD HAVE RECEIVED SIGNIFICANT DAMAGE AND POSSIBLE RESULTED IN AN ACCIDENT.
NHTSA complaint #11233258 — an unverified report by a vehicle owner.