Cosco Grand Explorer booster cushions

TP 2436
Road Safety Leaflet #  D-2004-03 (E)



Dorel Juvenile Group U.S.A.
2525 State Street
Columbus Indiana, USA



Importer & Distributor:
Dorel Juvenile Group Canada 
12345 Albert Hudson
Montreal, Quebec

Media Contact:
Rick Leckner: 1-514-731-0000

Consumer Contact:
Dorel Juvenile Group USA: 1-800-536-1090

Models Affected and Model Numbers:
Cosco Grand Explorer: #22-29C BVK, # 22-29C OXF

Number of Units:

Dates of Manufacture:
February 3  to September 30, 2003

Geographic Distribution:
All across Canada

Transport Canada crash tested six Cosco Grand Explorer booster cushions and a seam separation of the plastic abdominal shield occurred in four of the units during the crash test. In all four instances, the seam separation generated a jagged shard, (see photograph #3) under the padded fabric cover in one specific area next to the child's abdominal area.

Background & Company Action:
Transport Canada immediately notified the Dorel Juvenile Group (DJG) representative of the first two test results where seam separation had occurred. The company responded by conducting additional crash tests to verify the Transport Canada test results. In addition, the company developed a repair kit to be sent out to consumers of the affected units. The company also crash tested the repair kit to ensure its effectiveness and the repaired unit passed. It is understood, at this time, that there are no affected booster cushions for sale in retail stores or in the DJG inventory warehouse.

Safety Risk:
DJG does not believe that the projected shard poses a serious safety related risk, because the jagged shard did not penetrate the soft cover pad. Nevertheless a plastic shield cover was developed by DJG to further protect the child’s abdomen from any shard that could develop as a result of a motor vehicle collision.

Consumer Recourse:
A consumer with an affected unit can call the Consumer Customer Service 1-800 number (1-800-536-1090) free of charge and identify their booster cushion to the customer service representative and provide their name and address. A repair kit will be mailed to the consumer free of charge without delay. A repair kit can also be requested through their website:

With respect to the 1,700 consumers who have mailed in registration cards, letters will be sent out to the consumers and kits will be mailed accordingly.

Shown below are three photographs of the Cosco Grand Explorer abdominal shield booster cushion.

1) Front overall view

2) Rear view of abdominal shield 

3) Post test - rear top view of resultant jagged shard

Transport Canada: 1-800-333-0371

Release Date: March 30, 2004