THOR MOTOR COACH Complaints

UNKNOWN: ABS INOPERATIVE Light, Traction Control INOPERATIVE Light, Hill Assist Unavailable Message, Cruise Control unavailable. I have also reported this under the Ford F53 Chassis, since I have found that many different makes and models of gas engined motorhomes built on the Ford F53 Chassis have the same issue that has been unrepairable for several years.

The rear emergency exit window fell off during travel. Being a large motorhome I do not know where or when it happened and was noticed upon arrival at home. It is likely it came detached in traffic. I do have the make or model of the window but the Thor DAX # is 0273323.

While driving on on Interstate 80 near exit 70 in Illinois the battery box containing 4 coach batteries dropped from under the vehicle onto the highway. We were able to pull off the interstate on the offramp at exit 70. It appears the small bracket was underrated for the structural loads or improperly welded by the OEM. In addition the Positive battery wire was chaffing on the step framework.

The Receiver Hitch manufactured by Lippert Components part #360-231 and install by Thor and standard equipment failed in use and almost lost towed vehicle on Interstate Highway. Receiver Hitch broke completely on one side and only had 25% still holding on other side when excessive swerving of towed car and noise of dragging tow bar made driver stop. Towed car weight was half of stated hitch rating so there was no expectation of failure of this nature. Researching failure after incident found many similar reports on Thor related forums and a recent NHTSA recall 23V-351 for similar Lippert hitch.

U-bolts on rear axle passenger curbside that holds suspension leaf spring to axle: One broke completely off and separated into two pieces dropping partial u-bolt to the ground, second u-bolt twisted. These u-bolts hold the axle under the suspension leaf spring. I have parts. Fortunately the motorhome was parked in a campsite. If we had been traveling on the highway, this broken part could have ended up in another vehicle windshield. If the second twisted u-bolt would also have failed while traveling, the axle may have come loose and possibly caused the motorhome to flip. The repair was completed at an authorized Ford repair facility. Dealership would not submit for warranty due to light surface rust. This is a Ford F53 chassis, built 12/14/2020 with 6,234 miles. Ford has 2 rear suspension recalls on this chassis that have been repaired. 04/05/2023U-bolt broke without any warning of problem.

While traveling on the highway, the solar panel situated atop the van flew off as a result of strong winds. Fortunately, there were no injuries, but this issue poses a significant risk of severe harm or even fatalities. The solar panel remains unaccounted for. It is noteworthy that other owners of the same vehicle have reported similar problems. I am in contact with a representative of the manufacturer, Thor, but an inspection has not been conducted yet. There were no warning indicators or messages to notify me that the solar panel had detached; instead, it was a passing motorist who alerted me to inspect my roof.

The generator sits 5 inches from the ground below the rear axle. It is not protected with any encasement, bump stops or axle shims. Please see Bulletin TSB-21-06 for using parts kit #0503506. I have contacted the dealer and manufacturer about this and the say that there was no recall on my vin# for this. They have not offered to do anything about my concerns. The dealer inspected before I purchased the vehicle on 10/21/2003. My concern is the generator will hit a bump and tear off and hit the driver behind me.

In November 2022 we discovered that both brackets holding the front nose piece to the frame had broken away. Then we discovered the wall on the front passenger side of the Motorhome had pulled away from the floor and left an inch gap between the floor and the wall. We were able to temporarily fix it until we arrived home and it sits in our driveway. Thinking maybe the broken brackets had caused the problem we removed the trim on both sides of the front. On the passenger side we found the screws were all broken off or pulled through the wall. On the drivers side it looks like it had already been fixed once, it was full of holes and there were two different types of screws. Watching a video of a similar fix on a Thor Challenger, whose drivers side wall pulled away he said according to Thor the screws should be 4 inches apart. The screws on our Hurricane we about 8 to 10 inches apart. I’ve included pictures of the broken brackets, and the opening between the floor and wall. The program wont let me include more than 3 pictures, but I have pictures of the holes on the walls we found after taking the trim down and the broken screws. I also have a video of the wall moving as we are driving down the road. We called Thor and they said our motorcoach is out of warranty and there are no recalls on the Hurricane. I do know Thor has a recall for the same issue on a different model, but they said it doesn’t pertain to the Hurricane. If the fiberglass nose had fallen off, it would have caused a serious accident.

Four times while driving, the STOP ENGINE light came on causing the vehicle to slow to 5 MPH--twice while I was on the freeway in busy traffic--very hazardous. Two different error codes showed after the check engine light came on and then after I stopped and restarted the engine a few hours later, the check engine lights turned off. I took it to a Freightliner repair dealer and the accelerator pedal was defective. I only had 9000+ miles on the vehicle. The error codes were: spn 2623 FMI: 4 oc:6 sa:0 and Spn 91: Spn: 2 oc:3 sa:0. Note: these codes totally reset as if nothing was wrong.

The front cap seperates from the frame rail. There is a recall in Canada for the same issue. Transport Canada Recall - 2023087 - THOR MOTOR COACH Issue: On certain motorhomes, the brackets for the front lower cap may not be attached properly. As a result, the brackets could loosen and separate from the vehicle. Safety Risk: A bracket that detaches from a vehicle could create a road hazard for others and increase the risk of a crash. Corrective Actions: Thor Motor Coach will notify owners by mail and instruct you to take your motorhome to a dealership to inspect the brackets for the front cap and replace the mounting hardware. The dealership will also install new brackets, if necessary.