2017 Thor Motor Coach Palazzo

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.

I am reporting a serious and repeated safety defect involving Hehr side windows installed on my 2018 Thor Palazzo 36.1 motorhome (VIN: [XXX] ). Multiple operable side windows on this RV have experienced adhesive bond failure between the scissor arm/operator mechanism and the vent glass pane. This has caused windows to partially detach and violently flap while driving at highway speeds. One rear bathroom window completely detached and flew off the RV during highway travel in 2022. Additional adhesive failures have continued occurring from 2023 through 2025 involving: - Kitchen window - Living room window - Dinette window - Rear bathroom window (including replacement assembly) In several incidents, I was forced to pull onto the highway shoulder to perform emergency temporary repairs using tape and adhesive to prevent windows from fully detaching from the vehicle. In December 2025, while driving near [XXX] , the rear bathroom vent window again separated from the operator arm while traveling at highway speed despite prior repair work. The window was violently flapping in the wind and appeared at risk of completely detaching from the RV. This defect creates a serious road hazard because detached glass/window components could strike nearby vehicles or motorists. I am aware of prior Hehr/Lippert recalls involving adhesive-related window failures, but I have not found a recall covering this specific failure point involving separation between the operator arm and vent glass. The defect appears widespread across multiple windows on the RV and has persisted despite repeated repair attempts. I believe this issue warrants investigation and possible expansion of existing Hehr/Lippert window recalls. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11737992

Incident

Aug 8, 2022

AS I was driving mr rv. down the road , the rear side window just fell off onto the roadway. I believe the window is made by lippert. On the rv forum there are a lot of people experiencing this same problem.

NHTSA ID

11541771

Incident

Apr 2, 2023

The contact owns a 2017 Thor Motor Coach Palazzo RV. The contact stated while operating the vehicle, the rear marker light, and the driver side(left turn) signal were inoperable. The vehicle was taken to the local dealer to be serviced under the NHTSA Campaign Number: 21V00H000 (Electrical System, Exterior Lighting) which would address the failures but after the recall remedy was performed the failure persisted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 26,000.

NHTSA ID

11479345

Incident

Aug 8, 2022

Mileage

26,000 mi

WHILE STATIONARY, FIRST LARGE WINDOW BEHIND DRIVER'S SIDE BROKE OFF, AT THE TOP HINGE, FOR NO REASON. IF THIS HAD HAPPENED WHILE DRIVING, IT COULD HAVE CAUSED SERIOUS HARM TO FELLOW MOTORISTS. AT THE TIME THIS HAPPENED, I WAS UNAWARE OF THIS WEBSITE AND THE ABILITY TO REPORT.*DT

NHTSA ID

11361051

Incident

May 9, 2019

Mileage

5,000 mi

WHEN PARKED IN A PARKING LOT AFTER A 1HR DRIVE, THE ONLY EXIT DOOR THE VEHICLE HAS DID NOT OPEN, PREVENTING US FROM EXITING THE VEHICLE. OTHER CAMPERS PARKED IN THE SAME LOT WERE UNABLE TO OPEN THE DOOR FORM THE OUTSIDE BUT ABLE TO HAND ME TOOLS TO TAKE THE LOCK APART FROM THE INSIDE AND OPEN THE DOOR USING PLIERS AND A SCREW DRIVER. THE DOOR LATCH MADE OF A ZINC OR SIMILAR DIE CASTING HAND BROKEN IN HALF PREVENTING THE RETRACTION OF THE LATCH AND KEEPING THE DOOR LATCHED.

NHTSA ID

11343363

Incident

Jul 25, 2020

Mileage

12,000 mi

WHILE DRIVING THE RV, THE WINDOW ABOVE THE SINK SEPARATED. THE WINDOW IS DOUBLE PANED. THE OUTER GLASS PULLED AWAY AND WAS FLAPPING, CAUSING THE INTERIOR GLASS TO ALSO START PULLING AWAY. WE WERE ON A STRETCH OF HIGHWAY THAT WAS BUSY WITH TRUCKS, APPROX 6:30PM (DARK), 2 LANES EASTBOUND I-40 IN CALIFORNIA. THERE WERE NO EXITS FOR 20-25 MILES AFTER THE INCIDENT BEGAN. THE WINDOW CONTINUED TO BANG AND PULL AWAY THE ENTIRE DRIVE. THE PULL FROM THE WIND THREATENED TO COMPLETELY SEPARATE THE WINDOW ASSEMBLY FROM THE RV. THE HIGHWAY SHOULDER WAS NARROW WITH A DROP OFF SO WE DID NOT PULL OVER AS THIS WOULD ALSO NOT BE A SAFE SOLUTION.

NHTSA ID

11315770

Incident

Mar 2, 2020

Mileage

15,815 mi

The overhead cabinets located above the driver and front passenger seats may become loose during travel. This Technical Service Bulletin will be gathering information regarding this possible concern and will provide guidance on how to ensure the overhead cabinets are properly secured in the motorhome.