2022 Thor Motor Coach Hurricane

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.

The front cap seperates from the frame rail. There is a recall in Canada for the same issue. Transport Canada Recall - 2023087 - THOR MOTOR COACH Issue: On certain motorhomes, the brackets for the front lower cap may not be attached properly. As a result, the brackets could loosen and separate from the vehicle. Safety Risk: A bracket that detaches from a vehicle could create a road hazard for others and increase the risk of a crash. Corrective Actions: Thor Motor Coach will notify owners by mail and instruct you to take your motorhome to a dealership to inspect the brackets for the front cap and replace the mounting hardware. The dealership will also install new brackets, if necessary.

NHTSA ID

11545613

Incident

Apr 25, 2023

Wood stiles are delaminating due to the vendor changing the glue used for the wrapped stiles.

During production, the FM antenna was not included on the new 32” Connex Entertainment TVs (TMC Part # 484102). These TVs have a built in radio tuner, and the reception will be poor without the antenna

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