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Electrical system

Keystone Cougar Electrical problems by year

13 complaints filed with NHTSA about the Keystone Cougar's electrical system. Dead batteries, warning lights, wiring, alternators, infotainment and electronic module failures.

Electrical complaints by model year

YearElectrical complaintsCrashesInjuriesRecalls
20261000
20220001
20210002
20201001
20191000
20181000
20171001
20161000
20151000
20141000
20131000
20121000
20111001
20051000
20041000

Electrical recalls

Latest Cougar electrical complaints

2026 Keystone CougarElectrical systemBrakes

Brand new travel trailer delivered from the factory with damaged brake electrical connector to the ABS Module. This resulted in an immediate and total loss of trailer braking capability while towing the vehicle, creating an extreme safety hazard and increased stopping distances on public roads. I was able to reach my destination with extreme caution and upon investigation I found the clip that's supposed to keep the connector securely in place, completely severed and the entire harness loose and disconnected.

Filed Incident Electrical system · Service brakes · Service brakes, airNHTSA 11769765
2020 Keystone CougarElectrical system

The contact owns a 2020 Keystone Cougar. The contact stated while the RV was stationary, the rear motor turned on independently and fractured the gears. The contact took the RV to an independent mechanic, where it was diagnosed with needing the gearbox to be replaced. The RV was not repaired but was pending repairs. Upon investigation, the contact associated the failure with NHTSA Campaign Number: 19V689000 (Electrical System) however, the VIN was not included. A dealer was not contacted. The contact attempted to...

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reach the manufacturer by email but has not been able to reach a representative. The contact also stated that the battery was not holding a charge. The failure mileage was approximately 100.

Filed Incident Electrical systemNHTSA 11430579
2018 Keystone CougarElectrical system

My 2018 keystone cougar has had a electrical short in the bedroom slide. What has been of real concern is that the wires going through the trailer into the slide was incorrectly installed at the factory. The plastic protective grommet between the wires going from the trailer to the slide was left unsecured and allowed the wires to rub into (against the trailer frame)...Until a short occurred. The really bad thing was that the fuse in the panel did not blow depending on the position of the slide going in and out....

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It allowed the spring (holding the wires) underneath the bedroom slide to overheat to the point one couldn't touch it, and yet didn't blow the fuse sometimes. Extremely dangerous fire hazard in my opinion. It was fixed, but I have concern the rest of the electrical on the trailer should be checked, but have yet to receive a response from keystone about that request. Trailer was parked in a rv park.

Filed Incident Electrical systemNHTSA 11221294
2019 Keystone CougarBrakesElectrical system

Tl* the contact owns a 2019 keystone cougar. While driving and making a right turn, the emergency brake release cable separated and became caught underneath the towing vehicle. As a result, the vehicle straightened up and the trailer brakes seized, which resulted in the trailer being dragged for approximately four miles. The contact was alerted by another motorist about the trailer being dragged and that the wheels on the trailer were smoking. The contact turned the vehicle around and drove back home. Contact...

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noticed and smelled burning brakes. The contact inspected the trailer brakes and found that the brake release cable had detached and caused the failure. Consumer returned to cab of truck to inspect brake controller settings, which was not the problem. Decide to move vehicle and trailer nacho pavement to see if the brakes had released, drove around the block when realized they had not, pulled trailer into back yard to drop, walked toward nose of trailer and noticed breakaway cable disengaged from the trailer at the switch. Opened tailgate and found entire cable, truck end attached at hitch handle switch interlock end in the bed of the truck and cable pinched under bracket of the glider hitch. Reattached, emptied trailer, called repairman at bogue rv to get his take on possible damage, said he was concerned over the wheel bearings having been destroyed from the heat. Waited again for the brakes to cool, hooked next day, tested for disengagement of brakes after ensuring switch cable was free from catching on tested forward and backward motion without dragging of trailer, then drove trailer 14 miles to rv dealer for inspection and repair.The contact called an unknown dealer and scheduled an appointment. The contact was able to untangle the brake release cable; therefore, the trailer brakes released and the trailer was able to roll freely. The vehicle was currently at the dealer for diagnosis and a repair estimate. The manufacturer stated that the brake release cable was not covered under warranty and promised the contact would receive a call from a supervisor. There was no mileage. *Dt *jb

Filed Incident Parking brake · Electrical systemNHTSA 11220036
2015 Keystone CougarElectrical systemBrakes

From the time I left the dealer lot, I never had brakes that worked properly. Increasing the output from the brake controller didn't help. The brakes would over heat and never felt that I had enough brake to stop the trailer/truck. Had the brakes checked by several rv dealers which led to an adjust only. Recent trip caused "hot" brakes/wheels and brake smell. Went to a facility that specializes in rv repair and told them to tear the system apart and fix the problem. They found not enough voltage at brakes. ...

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Further investigation found excessive length and small gage wire installed by manufacturer. Not enough current going to brakes. Keystone installed 14 gage wire and it should have been 12 gage.

Filed Incident Electrical system · Service brakesNHTSA 11022172
2014 Keystone CougarElectrical systemLightsBrakes

The electric brakes have a very flimsy connection behind each brake plate. A very small wire is exposed to the elements. In our case, something broke the wire and the brakes failed. Keystone had their dealer repair the wire to its original flimsy state. A few months ago the trailer brakes were irratic (unreliable). I took the trailer to repair facility. In searching for the problem, they discovered that the rubber gasket on all four inner grease seals were severely damaged because they were undersized. If...

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the grease isn't contained in the bearings, eventually the wheels will fall off. Pictures are attached. The heat in the interior lights has always been of concern. Pictures of a partially melted light bulb and lenses are attached. Various articles say glass will melt at 900f isn't a 900f a fire hazard. I replaced the bulbs with led's which was a simple process. I wrote to the president of keystone. He said the director of owner relations call me; she the conditions I reported were normal and that keystone wouldn't participate in fixing these issues nor reimburse me for fixing these problems.

Filed Incident Electrical system · Exterior lighting · Service brakesNHTSA 10885443
2016 Keystone CougarElectrical systemBrakes

I purchased a new travel trailer manufactured by keystone in may of 2015. I took it back to the dealer after my first trip when I realized the brakes barely functioned. After 4 months of trying to get the manufacture to acknowledge the brakes did not work from the factory keystone stated that they felt the brakes functioned properly. The dealer, rcd sales agreed with me that the brakes did not work and they had a second 2016 trailer on their lot which the brakes did not function either and they were scared to sale...

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it. I reviewed the brakes myself they weekend and discovered that the wiring used by the manufacture was too small. There was nearly a 3 volt (25%) voltage drop from the wiring harness to the brake drums. After replacing what appeared to be 16 gauge wire with 12 gauge wire the brakes now work properly. Keystone however is still manufacturing trailers with inadequate braking caused by undersized wiring and insisting they are safe.

Filed Incident Electrical system · Service brakesNHTSA 10747990
2013 Keystone CougarElectrical systemFire

We own a 2013 keystone cougar 5th wheel model 331mks. On 4/4/14 we were at a campground and started to set up. The rig was only on 12v battery power. I had not yet connected to shore power. When I pushed the button to lower the landing gear, nothing happened. I tried the remote control, and nothing happened again. I went to get the power cord intending to plug it in. The cord was in the storage area in the front, under the hitch, where the battery is. When I opened the door, immediately smoke was billowing out....

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Then I saw the flame. It was coming from the circuit board above the battery.I immediately got the fire extinguisher. After using it several times, the flame kept coming back. I called 911 for the fire department. The propane tanks are right next to the area burning. I immediately removed both of them. All I could think of was the possibility of an explosion. The dispatcher asked if there was anything else nearby that could burn. I said "yes, it is connected to my truck which is full of diesel." I could imagine everything going up in smoke. I turned off the battery, turned off all the circuit breakers, but the flame kept coming back after I kept using the fire extinguisher.My wife went for the campground ranger. I finally emptied the fire extinguisher and the flame came back. I had nothing else to try, so I reached in and pulled the wires out which were all melted at and around the circuit board. The camp ranger told us that he had never seen anything like this before since it was not plugged into 110. I drove the rig to the dealer. At the dealership, 3 men came out to look. They said that they couldn't believe what they saw and that they had never seen this happen before. They took pictures. Our 5th wheel is now at the dealer. They said they will be talking to keystone on monday to see what next steps there are. *Tr

Filed Incident Electrical systemNHTSA 10577632
2012 Keystone CougarElectrical systemWheels & tiresBrakes

The electric brake wiring that connects the coach body to the front axle was rubbing on the inside sidewall of the lf tire of the trailer. It has rubbed a polished groove in the sidewall of the tire. The wiring connecting the rear axle to the coach was rubbing on the interior surface of the lr wheel. I secured the wiring away from the tire and wheel and returned the fifth wheel to the dealer where I purchased it. Keystone rv's attitude surprises me, they claim that the wire couldn't have been rubbing on the...

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tire and wheel, because the wire would have been instantly ripped off. I have pictures to prove the wiring job was inadequate and shoddy. This issue can't be an isolated incident. I feel that keystone needs to have it's dealers inspect all trailer brake wiring. If the wires had been torn loose or shorted out, my 9,000 pound fifth wheel would have become a giant weight pushing me down hills! This is a clear safety issue. Please let me know if you want my pictures forwarded to you. Thank you! *Tr updated 09/26/12*lj

Filed Incident Electrical system · Wheels · Service brakesNHTSA 10474175
2011 Keystone CougarElectrical system

Tl* the contact owns a 2011 keystone cougar fifth wheel trailer. The contact stated that while the air conditioner was in operation, the main circuit breaker would trip as a result of a wire shortage. In addition, the circuit breaker panel had become extremely hot to the touch. The failure recurred frequently. Prior to the failure, the vehicle was repaired under nhtsa campaign id number: 10v606000 (electrical system: fuses and circuit breakers). The remedy was not sufficient and the vehicle was taken back to the dealer for diagnosis where they were unable to diagnose a problem. The manufacturer was made aware of the defect. The failure mileage was unknown.

Filed Incident Electrical systemNHTSA 10417008
2005 Keystone CougarElectrical systemFire

On november 25, 2007 I was closing up my keystone courgar travel trailer after having used it for 4 days. After I slid in the two sideouts on the trailer I began to smell rubber burning and I began searching to see what was happening. I found flames inside and outside the trailer at the aft end of where the living room/dining room sideout mated to the trailer. I reopened the trailer, grabbed the fire extinguisher, slide the sideouts out away to get to the flames and extinguish them. If I had not noticed it as soon...

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as I did I could have been driving down the road fanning the flames and creating a serious hazard to others not to mention my wife and myself. It appears to have been caused by an electrical problem but that is undetermined at this time. *Tr

Filed Incident Electrical systemNHTSA 10210049
2004 Keystone CougarElectrical system

While operation of the lippert slideout in our '04 keystone 285efs fifth wheel, the slide stopped. Upon investigation (following wires, checking fuse, contacts, etc.) I found burnt out and melted wire nuts directly behind the fuse panel lying in sawdust. The wires are 10 gauge (30 amp). One stripped end was an inch in length while the other was less than 1/16". These wires provide full 12 volt amperage to operate the slideout. This way of stripping wires for wire nut attachment is not prudent for a safe electrical...

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connection and is extremely dangerous. I would believe that keystone should use "barrel connectors" for this extreme amperage and not plastic wire-nuts with improperly stripped wires. There's members on the keystone rv camping group sight that have also experienced this type of "burn-out". This can and could have been deadly. The 30 amp breaker never tripped. I also took pictures. *Nm

Filed Incident Electrical systemNHTSA 10179243

Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked daily. Complaints are owners' own reports and are not verified. How we use the data

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