2018 Thor Motor Coach Outlaw

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.

Windows have detached from adhesive and the window does not shut or seal. There is a recall on the windows for this problem but when I put my vin number in here it does not come up as a recall.

NHTSA ID

11713414

Incident

Jan 5, 2026

Lippert tow hitch (part#360231) Failure - hitch is known to shear off of rig when towing.

NHTSA ID

11661999

Incident

Sep 18, 2021

the coach has a know design flaw its in the what the walls are attached to the flooring of the coach....the design was under spec'ed (9) 3" screws over a 55" span approx 9-10" apart) and the hardware used was put under excessive force causing the screws used to hold the walls in place and attached to the floor to sheer and break causing the walls to separate from the floor and the coach structure to become comprimised , with wall sag , wall separations gapping between the walls and floor and excessive dash bouncing while driving once these screws sheered the rest of the structure becomes weak causing other structure concerns... this has been brought to the manufactures attention in multiple emails to the warranty division and in the industry its known as "Thor wall separation" I took it upon myself to do a precautionary inspection as ive recently started to have a bit of dash bouncing upon my inspection I found at least 60% of the screws holding my walls (Driver & Pass) broken I took it upon myself to speak with local dealer whom Thor recommended and got the details on how "they" fix the problem I made the repairs and even took it a level above adding extra structure to support the walls and added extra screws 6" apart for a total of (14 screws over the 55" span approx 6" apart ) the history of this issue is as far back as 2016 and is seen on newer 2020 Thor models outside of the "Outlaw" model

NHTSA ID

11459148

Incident

Mar 31, 2021

The contact owns a 2018 Thor Outlaw RV. The contact stated while driving approximately 55 MPH, the chassis was rattling and shaking. The contact pulled off the road safely. The contact stated no warning light was illuminated. The contact took the vehicle to the local dealer, where it was not diagnosed or repaired for the chassis failure. The manufacturer had been informed of the failure. The failure mileage was approximately 4,000.

NHTSA ID

11456645

Incident

Sep 7, 2020

Mileage

4,000 mi

It seems that Thor did not install the proper amount of wall screws to the floor. This is causing wall separation the causing the dash to come loose from the walls and cause the steering column to be unstable This is a high rate of failure on these units on the Thor outlaw toy hauler models

NHTSA ID

11443538

Incident

Nov 1, 2021

TL* THE CONTACT OWNS A 2018 THOR OUTLAW 37RB. THE CONTACT STATED THAT THE BODY OF THE VEHICLE SEPARATED FROM THE FLOOR OF THE CHASSIS. ADDITIONALLY, THERE WERE CRACKS ON THE CENTER REAR AND BOTH SIDES OF THE FRONT AND REAR OF THE VEHICLE. THE CONTACT CALLED CAMPING WORLD OF SYRACUSE AT 888-803-3193 (LOCATED AT 7030 INTERSTATE ISLAND RD, SYRACUSE, NY 13209) AND WAS REFERRED TO THE MANUFACTURER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT IT WAS A KNOWN FAILURE THAT THE MANUFACTURER WAS ATTEMPTING TO RESOLVE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 15,000. *DT *DT*JB CONSUMER STATED CHASSIS IS A F26 AND IS NOT A F53 AS PER VIN# OR BROCHURE. STRUCTURAL DAMAGE FRONT PASSENGER SIDE (TEMPORARY FIX HAS NOW FAILED) I HAVE A 1' GAP BETWEEN THE FLOOR AND WALL. THE WALL HAD DROPPED 1', BUT WAS PUSHED UP BY RTS (TRUCK SHOP)(GAP HAS REAPPEARED AND IS WORSE) FRONT DRIVERS SIDE (WALL IS DROPPING AND WRACKING) REAR DRIVERS SIDE (CRACKED AND WRACKING) REAR PASSENGER SIDE (CRACKED AND WRACKING) REAR CENTER TOP (ABOVE RAMP) (CRACK AND ROOF DAMAGE) REAR ROOF DAMAGE, INCLUDING OPEN CAULK AND CRACKS TO CAULK (LEAKING) THOR WILL NOT ALLOW ME TO PATCH THIS. MOVEMENT KITCHEN CABINET TO WALL SEPARATION IS BEING NOTED FROM THE WALL SEPARATION SCREWS ARE COMING OUT OF SLIDING DOOR BETWEEN BEDROOM AND GARAGE, CAUSED BY WRACKING OF REAR OF RV. REAR OF RV SHAKES. SCREWS ARE COMING OUT OF STEP/FLOOR AREA OF GARAGE, CAUSED BY WRACKING OF WALLS OF THE REAR OF THE RV THE DASH IS VIBRATING SO BAD THAT WIRES HAVE HAD TO BE RECONNECTED HAS CUT THE VINYL IN THE DASH FROM MOVEMENT, GPS HAS STOPPED WORKING, RADIO WILL NOT WORK. IS SO BAD. MICROWAVE SHAKES AND OPENS DOOR GOING DOWN THE ROAD. THERE ARE NUMEROUS PROBLEMS WITH VEHICLE TO NAME ALL. PLEASE SEE ATTACHMENT.*JB

NHTSA ID

11230993

Incident

Jan 21, 2019

Mileage

15,000 mi

TL* THE CONTACT OWNS A 2018 THOR OUTLAW. THE CONTACT EXPERIENCED SEVERAL ELECTRICAL FAILURES WITH THE VEHICLE. THE CONTACT STATED THAT THE VEHICLE STALLED AND THERE WERE FAILURES WITH THE SINK AND DRAIN. ALSO, SIX OF THE TWELVE BOLTS WERE STRIPPED. THE DEALER (MOTOR HOME SPECIALIST, 5411 S INTERSTATE 35 W, ALVARADO, TX 76009, (817) 790-7771) WHO SOLD THE CONTACT THE VEHICLE INDICATED THAT THE FACTORY OEM BOLTS WERE TOO SHORT ASSOCIATED WITH THE RAMP AND DOOR OF THE GARAGE UNIT AREA WHERE THE MOTORCYCLE WAS HOUSED. THE DEALER PERFORMED SEVERAL REPAIRS, BUT THE CONTACT CONTINUED TO EXPERIENCE MULTIPLE FAILURES. THE VEHICLE WAS ALSO SERVICED BY CAMPING WORLD OF TUCSON (4700 S PALO VERDE RD, TUCSON, AZ 85714, (888) 471-5280) WHO PROVIDED FURTHER DIAGNOSTIC TESTING AND REPAIRS. THE MANUFACTURER WAS CONTACTED NUMEROUS TIMES AND FAILED TO PROVIDE A SOLUTION. THE FAILURE MILEAGE WAS NOT AVAILABLE. *TT *TR

NHTSA ID

11083144

Incident

Jan 10, 2018

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.