2022 Thor Motor Coach Palazzo

The contact owns a 2022 Thor Motor Coach Pallazo RV built on a 2022 Freightliner XC-S Chassis. The contact stated that while driving approximately 55-60 MPH, the front cap was shuddering, and the contact noticed that the windshield was abnormally moving from side to side. Additionally, a prior crack on the windshield was expanding due to the failure. The contact stated that upon arriving at the residence, the contact became aware that the windshield had cracked significantly. The RV was taken to an Auto Glass Shop, and the windshield was replaced. The contact was informed that upon installing the windshield, the windshield was 1-2 inches too low due to defective brackets. The RV was taken to the dealer. The dealer determined that the brackets needed to be reglued, and new bolts needed to be installed and tightened on the vertical side rails. The dealer performed the repairs according to the Manufacturer's instructions; however, the windshield continued to move abnormally from side to side while driving. The RV was not repaired. The failure mileage was approximately 13,160.

NHTSA ID

11688342

Incident

Jul 10, 2025

Mileage

13,160 mi

Re: NHTSA #21V-921 Referring to this recall, when Freightliner performed this recall, they removed the stem extension without replacing it with a properly functioning stem extension. I consider this repair to be unacceptable as it does not provide access to the air stem on the inner rear tires without having to jack up the Motorhome and crawling underneath the vehicle. Properly functioning stem extension are readily available as millions of Semi Trucks operate with them daily. I have tried to contact Freightliner’s Warranty Dept. without benefit of a reply. It is my evaluation that this recall has not been properly performed.02

NHTSA ID

11513309

Incident

Feb 23, 2023

The Thor Palazzo has 2 braces in the front "nose" area of the coach-these braces are metal brackets that attach the front fiberglass nose to the area that contains the generator and fans for the air conditioner and other front-end components. These braces attach at both ends: the front part of the brace attaches w/ screws to a piece of wood that is then screwed into the fiberglass on the very front of the motorhome. The back side of the brace is attached w/ screws to a metal piece. This bracket acts as a support to the front windshield of the coach. This piece of metal on the passenger side of the motorhome came completely off & was drug under the front of the motorhome. Luckily, we were at an intersection when this happened and were able to retrieve the piece of metal. Had this piece came off when we were driving on the interstate, it could have been deadly. The piece measures about 15" in length & is heavy metal. It could have damaged the motorhome, tow vehicle, cars driving around us or become a projectile and flew into the windshields of cars behind us injuring others. We found the other bracket on the driver's side to be detached on one side and it pulled off with little resistance using one hand, so it was close to coming off as well. The brackets are attached with screws that had either come loose, had been sheared off or were missing. We had a couple of screws that were hanging underneath the front fiberglass nose. We have taken this to our dealership where it is currently being worked on and Thor Motor Coach has been notified. In searching this online, this has happened to several other Palazzo owners, but the design is still being used. We had no notice that this was an issue until it happened to us. Without the brackets, the windshield is not supported as it should be and driving to the dealership we had quite a bit of movement in the motorhome windshield.

NHTSA ID

11494085

Incident

Oct 14, 2022

On several occasions, I have received a "High Tire Pressure" warning indicating that one of my tires is either too hot or the pressure is excessive. On other occasions, I have gotten a High Tire Temperature Warning. Daimler Truck North America issued a campaign on this (number SF644A-C) and I took my motorhome in to get repaired. They reprogramed the TPMS computer. However, I am still having problems. I have contacted the dealer, they tell me they do not know of any other repairs or campaigns for this issue and there is nothing that can be done at the moment. This issue is extremely nerve-racking when the alert comes up on my dash while I am on the highway. I am in constant fear that one of time tires will blow out if i ignore the warning, but again there is nothing I can do. I would like them to examine this issue and replace all the sensors/computers if needed. Thank you. 22V-379 JPH 6.7.22

NHTSA ID

11467874

Incident

May 30, 2022

If a customer is experiencing inconsistent inverter readings on the Firefly panel, please utilize the below instructions.

On certain Detroit Model 2 and 3 steer axles, the tie rod arm and steering arm bolts used to assemble front axle assemblies have a lengthwise “seam” defect which increases stress concentration, potentially leading to bolt failure or loss of pre-load This affects the following Thor Motor Coach products: model year 2022 Aria, Palazzo, and Venetian motorhomes.

On certain Detroit Model 2 and 3 steer axles, the tie rod arm and steering arm bolts used to assemble front axle assemblies have a lengthwise “seam” defect which increases stress concentration, potentially leading to bolt failure or loss of pre-load This affects the following Thor Motor Coach products: model year 2022 Aria, Palazzo, and Venetian motorhomes.