2014 Thor Motor Coach Challenger

On November 23, 2020, the Office of Defects Investigation (ODI) opened PE20021 to investigate allegations of inoperative Trimark THP 060-1650 door lock/latches originally equipped on model years (MY) 2015-2017 Class A and Class C motorhomes.ODI received forty-six Vehicle Owner’s Questionnaires (VOQs) describing consumers being locked in or out of their vehicles.The door latch, containing a die-cast zinc plunger, was produced by Equality during calendar years 2014-2016. The die-cast may become porous and brittle over time and can break without warning, causing the vehicle owner to be unable to open the recreational vehicle door equipped with the latch.If the motorhome does not have any other doors such as some Class A models, occupants could be trapped inside, needing to climb out using the emergency exits. If locked out, owners would be unable to easily get in and retrieve children and pets. ODI analyzed the data provided by Trimark in response to its January 27, 2021 information request letter.Although an elevated failure rate was evident on a specific combination of plunger bolt, door lock/latch assembly and door, the data showed that most failures occurred within the first two years of service on the affected 2015-2017 vehicles.This data suggests that component failures generally would have already occurred.Further, ODI data reflects a downward trend in complaints after calendar year 2018 and for post- MY 2016 vehicles.This downward trend may be attributed Trimark's actions in 2016 such as changes in the manufacturing process of its zinc plunger component for the relevant population and its 2016 decision to switch to a steel plunger. In view of the nature of early-life failure, and failure rate trending downward for model years 2017 and newer, this Preliminary Evaluation (PE) is closed.  The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

To Whom It May Concern, I am submitting this complaint regarding Recall #21V-522 (NHTSA Campaign No. 21V-522) involving Lippert/Hehr windows. I own a 2019 Thor Motor Coach Challenger motorhome manufactured on 9/2018, which contains Lippert/Hehr windows that are exhibiting the same safety defect identified in this recall. Specifically, the adhesive bond between the glass and its supporting frame/rail has failed, causing partial detachment of the glass panel. While Lippert has stated that my windows are not covered because they were manufactured just prior to the official recall window, and that the defect is not a “seal failure” but rather a “rail detachment,” the functional hazard is identical: the glass panel is separating from the frame, creating a serious risk of detachment while in transit. I have already submitted extensive documentation to Lippert, including: •Photos of each affected window (interior and exterior). •Close-up photos showing the adhesive/rail detachment. •The official recall schematic identifying the part numbers of my windows, which match those identified in Recall #21V-522. Despite this, Lippert has refused to cover the repair under the recall, citing narrow technical distinctions and manufacturing dates. This refusal leaves me with multiple windows in my vehicle that present a significant public safety hazard consistent with the very defect NHTSA recognized in this recall. I am requesting that NHTSA review my case and determine whether Lippert is improperly limiting the scope of Recall #21V-522, and to require them to provide an appropriate remedy for my affected windows. Thank you for your attention to this matter. I am prepared to provide all supporting documentation, including photographs, correspondence with Lippert, and recall documentation, upon request. Respectfully [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11681808

Incident

Jul 16, 2025

The contact owns a 2014 Thor Challenger RV. The contact stated that while driving approximately 55 MPH in a heavy rainstorm, the windshield wipers became inoperable, creating a visibility hazard for the driver. The contact stated that during the failure, the windshield wiper setting was set to high speed; however, the windshield wiper module failed. The cause of the failure was not yet determined. The manufacturer was notified of the failure and informed the contact that the RV was previously serviced under NHTSA Campaign Number: 17V162000 (Visibility). The local dealer was not yet contacted. The failure mileage was 50,000.

NHTSA ID

11536964

Incident

May 1, 2023

Mileage

50,000 mi

TL* THE CONTACT OWNS A 2013 THOR CHALLENGER 37K. WHILE INSIDE THE RV, THE CONTACT ATTEMPTED TO OPEN THE DOOR; HOWEVER, THE DOOR FAILED TO UNLOCK. THE CONTACT HAD TO DRIVE THE RV TO THE DEALER (EXIT 1 RV, FAIRHAVEN, VERMONT) WHERE THE DOOR WAS REMOVED IN ORDER FOR THE CONTACT TO EXIT THE RV. THE DEALER REMOVED THE LATCH LOCK FROM THE DOOR OF THE RV; HOWEVER, THEY DID NOT HAVE A REPLACEMENT FOR THE DOOR LATCH AT THAT TIME. THE RV WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 25,000. THE VIN WAS UNKNOWN.

NHTSA ID

11277308

Incident

Oct 17, 2019

Mileage

25,000 mi

MY WIFE AND I TOOK DELIVERY OF OUR THOR RV AT 7PM ON 12/05/14 WITHOUT THE BENEFIT OF EVER BEING ALLOWED TO TEST DRIVE THE RV. MANY EXCUSES BY CAMPING WORLD. LEFT DEALER AND DROVE 300 YEARS ON NEARBY SURFACE ROAD AND BRAKED TO JOIN ENTRANCE RAMP TO INTERSTATE 75. BRAKES FAILED BECAUSE 3 POUND, RIGID 4 FOOT VINYL-CLAD, WOODEN FRAME COVERING HAD DISLODGED FROM THE ELECTRIC OVERHEAD BUNK FRAME AND DROPPED TO THE DRIVER'S FLOOR BEHIND BRAKE AND GAS PEDALS. COULD NOT SLOW COACH FROM 35MPH BUT FORCED TO THE SHOULDER OF ROAD UNDER OVERHEAD INTERSTATE EXCHANGE. TO STOP RV, DRIVER HAD TO DOWNSHIFT, THEN PLACE RV INTO NEUTRAL AND EVENTUALLY ENGAGE EMERGENCY BRAKE AS RV CAREENED TO A STOP ON GRASSY SHOULDER JUST BEFORE SPLASHING INTO A 2 ACRE, 6 FOOT DEEP WATER COLLECTION POND AT HIGHWAY EXIT. CAMPING WORLD STORE HAD CLOSED BUT WE DROVE BACK ANYWAY TO SEE IF WE COULD GET HELP. NO ONE WAS AVAILABLE. AT LEAST TWO COACH STEEL BRACE COVERS RISING FROM THE CAB FLOOR HAD BEEN PREVIOUSLY HELD IN PLACE WITH HOOK-AND-LOOP CLOSURE (VELCRO) FROM THE THOR FACTORY. VELCRO ADHESIVE HAD MELTED AND FLOOR SUPPORT COVERS DISLODGED ONCE COACH WAS DRIVEN AWAY FROM LOT. COACH HAD BEEN ON DEALER'S LOT FOR 12 MONTHS BEFORE OUR PURCHASE. EXCESSIVE HEAT AND HUMIDITY DEGRADED VELCRO ABILITY TO HOLD THE THREE POUND FRAME PROTECTION IN PLACE. REPORTED ISSUE TO RV DEALER AND THEY ATTEMPTED REPAIR. REPAIR NOT ACCEPTABLE. OWNER DRILLED THROUGH VINYL COVER AND WOOD STRUCTURE INTO STEEL BRACE TO SECURE BRACE COVER. INSTALLED VINYL BUTTONS FOR DRESS. SCARY, SCARY EPISODE. ALL THOR COACHES MUST BE INSPECTED - DEATH OR INJURY COULD OCCUR. VELCRO TAPES MUST BE REPLACED WITH VALID FASTENERS.

NHTSA ID

11100686

Incident

Dec 5, 2014

Mileage

1,344 mi

WHILE DRIVING IN HEAVY RAIN AT HIGHWAY SPEED MY WIPERS WENT ALL THE WAY TO THE DRIVER'S SIDE OF THE WINDSHIELD, AND STOPPED THERE. THOR ONCE REPLACED THEM BUT ABOUT A YEAR LATER THE NEW WIPER ASSEMBLY DID THE SAME THING UNDER THE SAME CONDITIONS. THROUGH ONLINE FORUMS I KNOW THAT SEVERAL OTHERS WITH THE SAME MODEL MOTOR HOME HAVE EXPERIENCED THE SAME OCCURRENCE. I CAN SUPPLY THEIR NAMES.

NHTSA ID

10909412

Incident

Sep 16, 2016

Mileage

36,000 mi

PASSENGER WIPER COMES LOOSE AT SPLINE AND FALLS BELOW WINDSHIELD. THIS HAPPENS WHEN TRAVELING AND WIPERS ARE IN USE.

NHTSA ID

10872519

Incident

Sep 15, 2013

Mileage

2,000 mi

This letter stated that there were no Service Bulletins or Technical Service Bulletins issued for the month of November, 2019.

This letter stated that there was one (1) Service Notification issued for the month of October, 2017.