2022 Thor Motor Coach Challenger

The Office of Defects Investigation (ODI) opened this Preliminary Evaluation, PE24023, on August 14, 2024, to investigate allegations of Thor Motor Coach motorhome frame or trailer hitch structure cracking and separating. The hitch was manufactured by Lippert and installed by Thor as standard original equipment. ODI received eight Vehicle Owner Questionnaires (VOQs) describing the hitch structure cracking. If not caught in time, a cracked hitch can fully fracture and separate from the vehicle. ODI sent information requests to Thor and Lippert on September 6, 2024 and September 27, 2024, respectively. Thor's full response was received October 31, 2024, and Lippert's full response was received December 6, 2024. ODI reviewed the responses and learned of improvements introduced to increase the overall strength of the system. The manufacturers reported 32 total incidents, and ODI is aware of 37 non-duplicative subject vehicle incidents in total, including four crash incidents where the towed vehicle separated and struck a roadside feature. The overall failure rate for all subject vehicles is low, and ODI isnot aware of any failures on vehicles produced in the last 30 months. Although a defect has not been identified, the manufacturers understand the seriousness of a potential hitch receiver structure failure. As a result, Thor, supported by Lippert, is conducting a customer satisfaction campaign that instructs consumers to inspect their hitch structure and informs what to look for and what to do if issues are found. If consumers areuncomfortable performing this inspection, Thor dealers can inspect the trailer hitch for them. The inspection and repair will be done at no expense to the consumer. ODI is closing this Preliminary Evaluation (PE) with this manufacturer action. 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.

Tow hitch cracked and separated

NHTSA ID

11740136

Incident

May 26, 2026

The Receiver Hitch manufactured by Lippert Components part #360-231 and install by Thor and standard equipment failed in use and almost lost towed vehicle on Interstate Highway. Receiver Hitch broke completely on one side and only had 25% still holding on other side when excessive swerving of towed car and noise of dragging tow bar made driver stop. Towed car weight was half of stated hitch rating so there was no expectation of failure of this nature. Researching failure after incident found many similar reports on Thor related forums and a recent NHTSA recall 23V-351 for similar Lippert hitch.

NHTSA ID

11553386

Incident

Oct 25, 2023

Thor Motor Coach (TMC) has been made aware of several incidents involving trailer hitch receivers installed on motorhomes, similar to yours. These issues were caused by the use of drop hitches and hitch extensions that placed higher-than-expected forces on the hitch receiver assembly. If you use your motorhome to tow, please follow the recommended instructions in your owner’s manual. THE USE OF DROP HITCHES AND/OR HITCH EXTENSIONS WHILE TOWING WILL PLACE LARGER STRESSES ON THE HITCH AND CAN LEAD TO FAILURE. TMC is requesting that you inspect your motorhome’s hitch receiver at your earliest convenience. Inspection instructions are enclosed with this letter. If you are unable or uncomfortable performing this inspection, contact your nearest TMC authorized dealer and they will inspect the trailer hitch for you. If any issues are found with your hitch or the mounting surfaces, please contact TMC Customer Service at 877-855-2867. TMC will coordinate and direct you to the nearest TMC authorized dealer for inspection and repair. The inspection and repair will be done at no expense to you.

On your vehicle, the rear axle may contain an inadequate volume of lubricating oil. An inadequate volume of rear axle lubricant may result in rear wheel bearing damage potentially leading to bearing seizure. Bearing seizure may lead to rear axle or driveshaft failure. A rear axle or driveshaft failure may result in loss of vehicle motive power, loss of transmission park function, and loss of parking brake function, increasing the risk of a crash. This affects the following Thor Motor Coach products: model year 2021/2022 Ace, Challenger, Freedom Traveler, Hurricane, Miramar, Outlaw, and Windsport motorhomes