2022 Forest River Xlr Toyhauler Problems

On 10/17/2025 while parked at Bethpage Campground in Urbanna, VA, the roof of our RV caught fire. The fire alarms did not sound the only indication was smoke filling the RV. Thankful this was during the day and we were awake. I felt the walls finding nothing hot then went outside and discovered the roof was on fire. I grab the fire extinguisher and climbed the ladder onto the roof and began putting out the fire. Attached are the pictures that show that there are screws/nails and a metal piece that goes through the wiring which caused the fire. I contacted Forest River and was told they would not cover any damages even though it was a manufacture defect and could have ending catastrophically if my family had been asleep.

The contact owns a 2022 Forest River XLR Toyhauler. Before purchasing the Toy Hauler, the contact noticed that the coupler had severe rust and was improperly welded. Upon investigation, the contact discovered NHTSA Campaign Number: 22V143000 (Equipment, Trailer Hitch) which she linked to the failure. The dealer agreed to make the needed repairs; however, upon delivery of the Toy Hauler, the coupler was spray painted to hide the damage and was not replaced. One day while using the microwave, the contact saw white smoke coming from the walls of the Toy Hauler and flames started coming from the walls. The contact used a fire extinguisher to put out the flames. The contact called the Fire Department who confirmed that the fire was caused by the electrical wiring inside the wall. A fire report was filed. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 22V135000 (Electrical System, Equipment). In addition, upon the use of the awning, the left side of the awning snapped and struck contact on the head. The contact was knocked unconscious but regained consciousness moments later. Medical attention was not sought. The contact linked the failure to NHTSA Campaign Number: 22V556000 (Equipment). The dealer and the manufacturer were notified several times of the failure but offered no assistance. The RV was not repaired. The failure mileage was unknown.

On 10/17/2025 while parked at Bethpage Campground in Urbanna, VA, the roof of our RV caught fire. The fire alarms did not sound the only indication was smoke filling the RV. Thankful this was during the day and we were awake. I felt the walls finding nothing hot then went outside and discovered the roof was on fire. I grab the fire extinguisher and climbed the ladder onto the roof and began putting out the fire. Attached are the pictures that show that there are screws/nails and a metal piece that goes through the wiring which caused the fire. I contacted Forest River and was told they would not cover any damages even though it was a manufacture defect and could have ending catastrophically if my family had been asleep.

My fuel station was not pumping fuel only air because the fuel pump line and fill neck vent hose line on the fuel station where installed from the manufacturer backwards not allowing the fuel to be picked up from the tank to the transfer pump. In an email from the fuel station manufacturer “Your particular unit came from Forest River Plant #79 and had a batch of these units where they installed the lines incorrect, not allowing the pump to pull any fuel.”

Electrical breakers continue to trip. Trim issues throughout along with floor bulking in kitchen. Both slides on on right side of camper leak when it rains. First trip out landing jacks did not work to level unit and one of the back glasses in the toy hauler scattered going down the road which was replaced with warranty. We have been trying to get the slide issue looked into for a couple of months but no luck getting a forest river tech to come assess and fix with the additional warranty purchased along with this unit. Have contacted manufacturer and was not helpful, they only referred places to carry to and would reimburse "some" of the cost. We are paying for a camper unit that is not up to standard for the price we paid for it especially having to wait 8 months after ordering it in June 2021 and we finally was able to pick up end of February 2022.

WE PURCHASED THIS RV 0N 1-25-2022 FROM DAY BROS RV SALES 3054 SOUTH LAUREL RD LONDON KY 40744 WE TOOK THE RV ON OUR FIRST VACATION TO FL IN FEB 2023 ON OUR WAY HOME FROM VACATION IN NORTH CAROLINA BOTH WHEELS CAME OFF THE RV WE ALMOST JACK KNIFED, THE WHEEL STUDS ON BOTH WHEELS BROKE OFF WE WERE STRAYED ON 95 NORTH FOR OVER 4 HOURS SITTING ON THE SIDE OF THE ROAD, A TROOPER STOPPED BY 45 MINUTES AFTER WE BROKE DOWN WE FINALLY GOT TOWED OF THE ROAD IT WAS ON SATURDAY FEB 25 2023 . THE TROOPER RECOMMENED MANGUMS TOWING AND ROAD SERVICES THEY REPLACES THE WHEEL HUBS NEW RIMS AND TIRES AT A COST OF 2010.69 WHICH I HAVE THE BILL FOR PLUS PICTURES OF THE BROKEN WHEEL STUDS THE DEALERSHIP HAS STILL NOT SAID ANYTHING ABOUT THIS PROBLEM PLUS THE 2010.69 FOR REPAIRS WE HAD TO LEAVE THE RV IN NORTH CAROLINA SO THEY COULD FIX IT WE HAD TO RENT ANOTHER VEHICLE TO GO HOME WHICH IS IN DELAWARE 6 HOURS AWAY A WEEK LATER WE PICKED THE RV UP CAN YOU PLEASE LOOK INTO THIS MATTER A BRAND NEW RV SHOULD NOT LOSE IT WHEELS PERIOD

Tire size: st 205 / 75 R 15 Returning ng home from a camping vacation. Traveling on interstate 10 east of San Antonio. Experienced a right rear blowout in a tandem axle camping trailer. Upon replacing damaged tire with included spare noticed considerable damage to wheel well from exploded tire. The tire’s tread had seperate exposing broken and separated belts. I was confused why brand new tires would explode as this one did. Also noticed that the 3 remaining tires looked different from the exact replacement spare tire. Spare tire looked normal but the three remaining tires looked like their center tread wanted to separate as well. We made it home. The tire is still available to inspect. Our lives were in danger because we had to pull over on the side of interstate and change tire. The tire was available for inspection by the insurance company but no comment was made.

My fuel station was not pumping fuel only air because the fuel pump line and fill neck vent hose line on the fuel station where installed from the manufacturer backwards not allowing the fuel to be picked up from the tank to the transfer pump. In an email from the fuel station manufacturer “Your particular unit came from Forest River Plant #79 and had a batch of these units where they installed the lines incorrect, not allowing the pump to pull any fuel.”

The failure involves the trailer brake wiring system. The brake wiring harness near the rear bathroom plumbing exit is improperly routed and installed in direct proximity to moving suspension components. This has resulted in repeated abrasion and damage to the brake wiring, causing intermittent and reduced braking capability. The affected components are available for inspection upon request. This condition presents a serious safety hazard. The trailer (approx. 18,000 lbs GVW) experienced degraded braking performance, significantly increasing stopping distance and risk of loss of control, particularly at highway speeds or during emergency braking. This creates a substantial risk to the operator, passengers, and the public. The defect has occurred multiple times and is reproducible. The brake wiring has been damaged on at least three separate occasions due to continued contact with suspension components. The failure location and mechanism have remained consistent, indicating a systemic design or manufacturing defect rather than normal wear or isolated damage. The condition has been visually confirmed during service and repair. Despite repeated failures, no permanent corrective action has been implemented by the manufacturer. There were no consistent warning indicators prior to failure. The primary symptom was reduced or inconsistent trailer braking, which progressed as the wiring became further compromised. Based on repeated failures and consistent damage location, this represents a design defect involving improper routing and inadequate clearance of critical safety systems. This condition may affect other similarly constructed units and warrants further investigation for potential recall or corrective action.