Thor Motor Coach ACE problems and owner complaints

AFTER SMELLING A BURNT SMELL, I INVESTIGATED AND FOUND BURNT AND MELTED WIRE NUTS WITHIN THE POWER TRANSFER SWITCH. NUMEROUS SAME ISSUES ARE REPORTED ON THE THOR RV BLOG SITE. IT APPEARS THAT THEH WIRE NUTS COMMONLY USED IN HOUSEHOLD CONSTRUCTION COME LOOSE WHEN USED IN A MOVING VEHICLE.

Look up ODI 11114432 at NHTSA ↗

THE ELECTRICAL WIRING WITHIN THE MOTOR COACH IS NOT TO NFPA'S NATIONAL ELECTRICAL CODE NOR IS IT WIRED TO THOR'S OWN FACTORY SPECIFICATIONS. IN ADDITION, THE APPLIANCES WITHIN THE COACH ARE NOT WIRED TO THE SPECIFICATIONS OF THE APPLIANCE MANUFACTURER. OUR MOTOR COACH EXPERIENCED A SHORTED WIRE IN THE WATER HEATER JUNCTION BOX DUE TO IMPROPER SPLICING IN AN AREA WHERE NO SPLICING SHOULD HAVE BEEN NECESSARY. THAT SAME ELECTRICAL CIRCUIT WHICH, PER THE NEC AND THOR'S FACTORY SPECIFICATIONS SHOULD HAVE BEEN ON A DEDICATED BREAKER, WAS NOT ON A DED…

Look up ODI 11084963 at NHTSA ↗

UNDERRATED CIRCUIT BREAKER, 15 AMP VICE 20 AMP, RATING FOR REAR AIR CONDITIONER. FORWARD AIR CONDITIONER, SAME MODEL AND SIZE, HAS CORRECT 20 AMP CIRCUIT BREAKER. OVERRATED FUSE D8, 20 AMP VICE 15 AMP, ON CEILING LIGHTS. THIS WAS FOUND WHILE STATIONARY TROUBLESHOOTING A WATER LEAK. I DECIDED TO SEE WHAT SPARE FUSES I MAY NEED AND I NOTED THESE DISCREPANCIES.

Look up ODI 11091394 at NHTSA ↗

SUBJECT VEHICLE HAD BUNDLED WIRES SIZE APPROX. #2 DOWN TO #10, WITH A MINIMUM OF 6 WIRES IN THE BUNDLE. WIRES MOSTLY ORIGINATED FROM BATTERY COMPARTMENT WHICH CONTAINS HOUSE BATTERIES AND WIRES FROM ENGINE BATTERY. WIRE BUNDLE WAS IN NO WAY BRACKETED OR HUNG FROM CLAMPS BUT WAS DRAPED OVER/ON THE DRIVE SHAFT NEAR A U JOINT. CONSTANT RUBBING EVENTUALLY WORE THROUGH THE WIRE INSULATION OF THE HEAVIEST WIRES (DC DIRECT FROM BATTERIES) AND SHORTED OUT AND CAUSED THE REMAINING WIRES TO SHORT AND BARE THEMSELVES POSSIBLY THROUGH FIRE. AT THE TIME…

Look up ODI 11289727 at NHTSA ↗

Returning home from trip, route US I26 in NC, heading down 6 degree hill lost all speed control. The following dash lights came on: ABS, Engine Service, the Wrench, anti sway control. We were able to roll to the side of the road just before an entrance ramp. There was no acceleration control.

Look up ODI 11438528 at NHTSA ↗

WINDSHIELD WIPERS STOPPED WORKING WHILE DRIVING ON I-95 IN NC DOING ABOUT 65 MPH IN A VERY HEAVY RAIN STORM AT NIGHT. THE NUT THAT HOLDS THE WIPER ARM ASSEMBLY TO THE WIPER MOTOR CAME OFF AND THE WIPER ARM ASSEMBLY SEPERATED FROM THE WIPER MOTOR CAUSING THE WINDSHIELD WIPERS TO STOPPED WORKING. VISIBILITY WHEN TO ZERO. LUCKILY THERE WAS AN EXIT TO GET OFF I-95. ONCE I TROUBLESHOOT THE PROBLEM I RE-ATTACHED THE WIPER ARM ASSEMBLY TO THE WIPER MOTOR AND I THEN REPLACED THE NUT WITH A REPLACEMENT NUT. THE AVERAGE PERSON DOES NOT HAVE AN AS…

Look up ODI 10925704 at NHTSA ↗

I purchased the motorhome from Fraserway RV in Kamloops, BC. The vehicle was sold to me as a new unused unit in November 2023. While turning into a strip mall parking lot from a small service road, we were travelling at around 5-10 KPH. My wife and I heard a very odd low "thud" type of noise coming from somewhere in the motorhome. We parked in the mall parking lot and began to look for the source of the noise. We were unable to find anything so we assumed perhaps something in a cupboard had shifted. We purchased some groceries and my wife decid…

Look up ODI 11594819 at NHTSA ↗

I AM EXTREMELY CONCERNED THAT RUNNING GAS LINES INTO AND THEN OUT OF AN OIL COOLER THAT IS ATTACHED TO THE FRONT OF THE RADIATOR AT THE FRONT OF A VEHICLE IS NOT SAFE. ANY FRONT END COLLISION COULD CAUSE THESE NEW LINES AND OR THE OIL COOLER TO BREAK CREATING THE POTENTIAL FOR A FIRE. I AM ATTACHING TWO PICTURES IN THE FIRST YOU CAN SEE THE OIL COOLER ATTACHED TO THE RADIATOR THROUGH THE FRONT GRILL OF THE VEHICLE, THE SECOND SHOWS A CLOSER VIEW OF THE OIL COOLER. THERE IS A THREAD WHICH HAS MORE PICTURES AND SOME OF THE OWNER'S REMARKS AS TO…

Look up ODI 10522371 at NHTSA ↗

TL* THE CONTACT OWNS A 2018 THOR ACE. WHILE DRIVING VARIOUS SPEEDS, THE STEERING WHEEL WAS EXTREMELY LOOSE, THE AUXILIARY BATTERY OVERHEATED, AND THE VEHICLE DECELERATED. IN ADDITION, THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. UPON OPENING THE HOOD, THE CONTACT NOTICED ACID EMERGING FROM THE AUXILIARY BATTERY. THE VEHICLE WAS TAKEN TO CAMPING WORLD OF ALBUQUERQUE (14303 CENTRAL AVE NW, ALBUQUERQUE, NM 8712[phone removed]) WHERE IT WAS DIAGNOSED THAT THE STABILIZER FOR THE FRONT AND REAR NEEDED TO BE REPLACED ALONG WITH THE AUXILIARY BATTER…

Look up ODI 11112225 at NHTSA ↗

SUBJECT VEHICLE HAD BUNDLED WIRES SIZE APPROX. #2 DOWN TO #10, WITH A MINIMUM OF 6 WIRES IN THE BUNDLE. WIRES MOSTLY ORIGINATED FROM BATTERY COMPARTMENT WHICH CONTAINS HOUSE BATTERIES AND WIRES FROM ENGINE BATTERY. WIRE BUNDLE WAS IN NO WAY BRACKETED OR HUNG FROM CLAMPS BUT WAS DRAPED OVER/ON THE DRIVE SHAFT NEAR A U JOINT. CONSTANT RUBBING EVENTUALLY WORE THROUGH THE WIRE INSULATION OF THE HEAVIEST WIRES (DC DIRECT FROM BATTERIES) AND SHORTED OUT AND CAUSED THE REMAINING WIRES TO SHORT AND BARE THEMSELVES POSSIBLY THROUGH FIRE. AT THE TIME…

Look up ODI 11289727 at NHTSA ↗

Returning home from trip, route US I26 in NC, heading down 6 degree hill lost all speed control. The following dash lights came on: ABS, Engine Service, the Wrench, anti sway control. We were able to roll to the side of the road just before an entrance ramp. There was no acceleration control.

Look up ODI 11438528 at NHTSA ↗

BOUGHT RV FALL 2017. WHILE PARKED IN GARAGE, COULDNT GET IN BECAUSE DOOR LOCKED BY ITSELF. HAD TO BREAK INTO RV AND TAKE DOOR HANDLE OFF AS KEYS WOULD NOT OPEN IT OR MANUAL OPERATION WOULD NOT OPEN IT. REFUSED TO PURCHASE ANOTHER REPLACEMENT FOR FEAR OF THIS HAPPENING AGAIN. VERY POOR DESIGN. THE POP ALUMINUM SLAVE BROKE WITH NORMAL OPENING AND CLOSING OF DOOR. WE JUST CAME BACK FROM A FAMILY VACATION AND WOULD HAVE HATED TO THINK WHAT WOULD/COULD HAVE HAPPENED WITH 2 SMALL DOGS AND 2 CHILDREN. *TT *JS

Look up ODI 11104930 at NHTSA ↗

CSPC: RV DOOR LATCH BROKE. WAS NOT ABLE TO EXIT THE VEHICLE. LATCH FRACTURED AND COULD NOT BE ACTUATED BY THE HANDLES. *DT *JS *TT

Look up ODI 11099648 at NHTSA ↗

TL* THE CONTACT OWNS A 2016 THOR ACE (MODEL 29.4) RECREATIONAL VEHICLE. THE CONTACT STATED THAT THE PASSENGER SIDE REAR ENTRY DOOR WAS UNABLE TO BE OPENED FROM INSIDE OR OUTSIDE THE VEHICLE DUE TO THE DOOR LATCH BEING FRACTURED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR REPAIRS. THE CONTACT LEFT A VOICEMAIL WITH THE THOR MANUFACTURER AT [phone removed], ALERTING THEM OF THE FAILURE. THE CONTACT WAS AWAITING A CALL BACK. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 14,391.

Look up ODI 11088692 at NHTSA ↗

TL* THE CONTACT OWNS A 2016 FORD F-53. THE CONTACT STATED THAT THE ENTRY DOOR LATCH MECHANISM FAILED TO LOCK THE RV DOOR. THE CONTACT WAS UNABLE TO ENTER THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 31,000. *DT*JB*PM CONSUMER STATED HE HAD A FAULTY LATCH.*JB

Look up ODI 11265710 at NHTSA ↗

BOUGHT RV FALL 2017. WHILE PARKED IN GARAGE, COULDNT GET IN BECAUSE DOOR LOCKED BY ITSELF. HAD TO BREAK INTO RV AND TAKE DOOR HANDLE OFF AS KEYS WOULD NOT OPEN IT OR MANUAL OPERATION WOULD NOT OPEN IT. REFUSED TO PURCHASE ANOTHER REPLACEMENT FOR FEAR OF THIS HAPPENING AGAIN. VERY POOR DESIGN. THE POP ALUMINUM SLAVE BROKE WITH NORMAL OPENING AND CLOSING OF DOOR. WE JUST CAME BACK FROM A FAMILY VACATION AND WOULD HAVE HATED TO THINK WHAT WOULD/COULD HAVE HAPPENED WITH 2 SMALL DOGS AND 2 CHILDREN. *TT *JS

Look up ODI 11104930 at NHTSA ↗

DOOR LATCH FAILED. WAS NOT ABLE TO EXIT VEHICLE. LATCH BROKE SO THAT LEVERS DID NOT ACTUATE THE LATCH.

Look up ODI 11098056 at NHTSA ↗

ON SEPTEMBER 22, 2018 I FOUND MYSELF TRAPPED INSIDE MY 2016 THOR ACE 30.1 MOTORHOME. THE DOOR LEVER THE DOOR, WHICH WAS NOT LOCKED, WOULD NOT OPEN. IT WAS OBVIOUS FROM THE WAY THE DOOR LEVEL PULLED THAT IT WAS NO LONGER CONNECTED TO THE LATCH. FORTUNATELY AT 73 YEARS OF AGE I AM STILL AGILE ENOUGH TO CLIMB OUT THE REAR ESCAPE WINDOW, SOMETHING THAT MY WIFE DUE TO SOME PHYSICAL LIMITATIONS COULD NEVER HAVE DONE. UPON TAKING THE MOTORHOME TO CAMPING WORLD THEIR TECHNICIAN HAD TO LITERALLY DRILL OUT THE MATERIAL AROUND THE DOOR LEVER TO GET TO T…

Look up ODI 11132271 at NHTSA ↗

TL* THE CONTACT OWNS A 2016 FORD F-53. THE CONTACT STATED THAT THE ENTRY DOOR LATCH MECHANISM FAILED TO LOCK THE RV DOOR. THE CONTACT WAS UNABLE TO ENTER THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 31,000. *DT*JB*PM CONSUMER STATED HE HAD A FAULTY LATCH.*JB

Look up ODI 11265710 at NHTSA ↗

WHILE DRIVING A 2013 THOR ACE MOTOR HOME AT 60 MPH I HEARD BEEPING NOISE IN THE DRIVERS AREA. WHILE TRYING TO FIGURE OUT THE SOURCE I DISCOVERED THE MOTOR HOME WAS ON FIRE UNDER THE RIGHT FRONT. THE LEVELING SYSTEM HAD TURNED ON THE HYDRAULIC PUMP AND ONE OF THE RETURN LINES WAS LEAKING. THE RESULTING HIGH PRESSURE HYDRAULIC FLUID WAS SPRAYING ON THE EXHAUST AND IGNITING. THE LEVELING SYSTEM IS USED FOR LEVELING THE VEHICLE WHILE PARKED. APPARENTLY THE SYSTEM IS DESIGNED SO THAT IF IT DETECTS ONE OF THE JACKS LOWERING WHILE DRIVING IT APPLIES H…

Look up ODI 10532936 at NHTSA ↗

HYDROLIC BOOSTER IS LEAKING INSIDE COACH AND DRIPPING UNDER BRAKE PEDAL. I NOTICE IT MORE WHEN ENGINE IS COLD.

Look up ODI 11109981 at NHTSA ↗

The initial brake pedal press is soft and travels nearly to the floorboard. A quick subsequent press of the brake pedal, or "pumping the brakes," changes the pedal travel and sensitivity. This condition has eluded repeated repair attempts by the service center and the chassis manufacturer's team of engineers. The chassis manufacturer has sent its engineers to the service location for hands-on evaluation and repair attempts, to no avail. Parts replaced during the service center's repair attempts include the calipers, pads & rotors, brake line…

Look up ODI 11515368 at NHTSA ↗

TL* THE CONTACT OWNS A 2014 THOR ACE. WHILE DRIVING VARIOUS SPEEDS IN THE RAIN, THE WINDSHIELD WIPERS FAILED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE RELAY BOX FILLED UP WITH WATER. THE VEHICLE'S RELAYS WERE REPLACED AND THE POSITION OF THE BOX WAS MOVED TO PREVENT WATER INTRUSION. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 17,000.

Look up ODI 10910798 at NHTSA ↗

TL* THE CONTACT OWNS A 2018 THOR ACE MOTOR HOME. THE CONTACT STATED THAT THE WINDSHIELD FLUID SPRAYER DID NOT SPRAY THE FLUID HIGH ENOUGH TO CLEAN THE ENTIRE WINDSHIELD. THE FAILURE CAUSED A BUILD-UP OF DEBRIS ON THE WINDSHIELD. THE VEHICLE WAS TAKEN TO CAMPING WORLD OF BAKERSFIELD [phone removed], LOCATED AT 5500 WIBLE RD, BAKERSFIELD, CA 93313) WHERE THE LINES WERE CHECKED TO MAKE SURE THEY WERE NOT CLOGGED. THE TECHNICIAN ALSO CHANGED THE WIPER BLADES, BUT THE FAILURE RECURRED. THE TECHNICIAN TOOK A PICTURE OF THE POSITION OF THE SPRAYER AND…

Look up ODI 11205894 at NHTSA ↗

The splines on the wiper arm connecting to the wiper motor control studs are stripped out on both the passenger and driver sides, rendering the wipers ineffective during rain. When driving at highway speeds, the only course of action is to pull over and wait for the rain to stop. I visited an RV repair facility, a Ford dealership parts department, and a diesel parts business to find a replacement. All three businesses confirmed that the wiper arm is irreparable and needs to be replaced.

Look up ODI 11598209 at NHTSA ↗

The contact owns a 2021 Thor Motor Coach Ace RV. The contact received notification of NHTSA Campaign Number: 21V202000 (Suspension, Power Train) however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The local dealer and the manufacturer were made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

Look up ODI 11435409 at NHTSA ↗

Rear Sway Bar Bracket manufactured from weak cast iron. Known problem and FORD will do nothing to fix it except to replace with same faulty part.

Look up ODI 11460377 at NHTSA ↗