2022 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.

I’m concerned about the bbq propane compartment getting hairline cracks and the brass shut off valve that’s made of brass and dropping down to the road and getting road rash till it grinds through the shut off valve. I just read on a Thor Facebook forum that this happened to a 2016 Thor Windsport 34P. I have the pictures he posted. I asked AI Gemini, apparently this is a known and well documented safety issue. I can forward the link to the AI report. Will link here if this works. The pictures are mine (intact) and the other two are his 2016 motorhome. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11743055

Incident

Jun 9, 2026

While driving on a crowded freeway a wooden structure fell from the ceiling of my motorhome and landed on the dashboard inches from my steering wheel. If it had hit my steering wheel or my hands, I would have been involved in a multiple vehicle collision. Thank God, I was able to safely pull over to the shoulder to check for damage. The beam was too heavy for me to move it. I drove it to a Camping World repair facility. The repair technician inspected the damage. He told me the support structure fell because it was held up by only one screw. Please note the comments for Job#4 in the repair invoice I hope to attach. I tried to upload some photos of the fallen structure, but I couldn't upload them. There were no warnings or symptoms of the defects. The damage was inspected and confirmed by the service technician of the New Braunfels, Texas Camping World. They reinforced the structure by mounting it with more screws, I do not know the size or number of screws installed. ( their is a typo in the job order document notes. I typed "Please Not comments for Job#4", it should be "Please note comments for Job#4". I anticipate a negative reaction by Thor Industries as I filed a Texas Lemon Law complaint because of many other defects and equipment failures in the motorhome. Part of the invoice includes a windshield wiper motor and gears that fell apart

NHTSA ID

11627339

Incident

Oct 9, 2024

The contact owns a 2022 Thor Motor Coach Windsport RV built on a 2020 Ford F-53 chassis. The contact stated that while driving at 65 MPH, a wooden beam used to deflect airflow from the outer venting fell from the ceiling of the RV. The heavy beam fell inches away from the contact's hands that were on the steering wheel. The contact pulled over after the failure but could not move the beam due to the weight. Despite the failure, the contact was able to drive the vehicle to the RV dealer where it remained. The manufacturer was notified of the failure but offered no assistance. The beam was reinstalled, and the RV was repaired. The contact expressed concerns that the failure might reoccur, and cause a severe crash. The failure mileage was approximately 14,000.

NHTSA ID

11620956

Incident

Oct 7, 2024

Mileage

14,000 mi

The propane heater on our motorhome has been cycling on the high limit switch since new. This is due to insufficient airflow across the heat exchanger. It is also the source of intermittent carbon monoxide alarms being activated. We have had this unsuccessfully repaired under warranty. The cycling continues. If other units of this model series were built the same way, I suspect this is a problem common to all. This also creates a fire risk should the high limit switch be operated enough times for it to fail. I am now using an electric heater, but this requires I be hooked up to electric service.

NHTSA ID

11590874

Incident

May 19, 2024

Main propane heater in my Thor Windsport 29M motorhome was coming on and goings on off before the desired temperature was reached. I realized it was cycling on the high limit switch, which is.generally caused by insufficient air flow over the heat exchanger. Took it in for warranty service which identified the cause as a kinked heater hose, which had to have been done at the factory during installation. Had the high limit switch failed, the motorhome would have been lost to a fire. Due to the high heat caused by the kinked duct, the blower wheel had partially melted.

NHTSA ID

11576418

Incident

Sep 1, 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

On your vehicle, it may be possible that the engine cover insulation does not fully extend to the perimeter of the factory engine cover. In addition, vehicles built on a Ford chassis may have higher engine compartment temperatures during certain idle conditions. This may result in elevated temperatures at certain areas of the engine cover surface in the passenger compartment on both driver and passenger sides. Direct and continuous contact with exposed skin at these locations may cause skin irritation and/or a minor burn. This affects the following Thor Motor Coach products: model year 2021/2022 Axis, Chateau, Coleman, Daybreak, Four Winds, Freedom Elite, Magnitude, Majestic, Outlaw, Quantum, and Vegas motorhomes.