2019 Thor Motor Coach Windsport

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 contact owns a 2019 Thor Windsport Motorhome built on a 2018 Ford F53 Chassis. The contact received notification of NHTSA Campaign Number: 20V804000 (Equipment). The contact took the vehicle to a dealer where the vehicle was serviced under recall. The contact stated that a year later, the contact stated while driving 30 MPH, the cabinet that was repaired under the recall fell down onto the dashboard while driving. The contact's wife had to manually lift part of the cabinet in order for the contact to resume normal driving. Once the contact reached his destination, he inspected the RV and saw that the cabinet was secured by self-tapping screws which was an inadequate repair for the cabinet. The contact purchased his own materials and was able to make minor repairs in order to safely drive home. The dealer was notified of the failure and informed him that the recall was already satisfied and that no other assistance could be offered. The contact also spoke with the manufacturer and filed a complaint. The RV was not repaired. The failure mileage was unknown. Consumer had their Motorhome since serviced and found a new problem , that resulted during that same time as the cabinet failure as consumer was driving. On that same trip consumer had a fire happen in the battery compartment of the motorhome. The shop that repaired the cabinet said the fire was a result of a battery cable coming from the engine battery to the motorhome battery compartment had fallen onto the drive shaft of the motorhome resulting in complete wear to the wiring and causing the wiring to short out causing tremendous heat to the wiring causing the fire.

NHTSA ID

11463860

Incident

May 1, 2022

This letter stated that there were no Service Bulletins or Technical Service Bulletins issued for the month of November, 2019.