Thor Motor Coach TUSCANY problems and owner complaints

EXTREAMLY RUSTED FASTENERS ATTACHING THE FOLDING STEPS TO THE BODY. THE MOTORHOME WAS STATIONARY WHEN DISCOVERY WAS MADE. IF THE STEPS HAD SEPARATED WHILE IN MOTION THEY WOULD HAVE BEEN RUN OVER BY THE RIGHT FRONT WHEEL AND THE REAR DUAL WHEELS. I AM ENCLOSING A PICTURE OF THE FASTENERS THAT WERE REMOVED AND THE STEPS AFTER REPAIR.

Look up ODI 10899285 at NHTSA ↗

FLOORS IN BOTTOM STORAGE BAYS ARE SAGGING AND BOWING ARE AT RISK OF FAILING OUT ON HIGH WAY. NEED TO BE REPLACED WITH BETTER MATERIAL .

Look up ODI 11327601 at NHTSA ↗

THE FLOORING IN THE UNDERSIDE PASS-THROUGH STORAGE COMPARTMENTS IS COMPOSED OF A VERY THIN LAYER OF PLYWOOD SANDWICHED BETWEEN TWO LAYERS OF A VERY THIN ALUMINUM. THIS MATERIAL IS NOT WATERPROOF AND HAS SEPARATED CAUSING THE FLOORING TO LOOSE IT'S RIGIDITY. THIS AREA IS NORMALLY USED TO STORE ITEMS LIKE GRILLS, CARPETS TENTS AND OTHER NECESSITIES WHILE TRAVELING. THESE ITEMS HAS THE FLOOR WEAKENS COULD POSSIBLY FALL THROUGH ON TO THE HIGHWAY CAUSING HAZARDOUS CONDITION FOR THE COACH AND OTHER VEHICLES TRAVELING ON THE HIGHWAY. THIS ISSUE WAS…

Look up ODI 11325290 at NHTSA ↗

Windows have detached from the vehicle while driving on two occasions. One was recovered on the shoulder of the highway, another quite large window was lost on the interstate and could have hit another vehicle. The Lippert windows are already the subject of a NHTSA safety recall (21V-522); however, even though the windows have experienced an adhesive failure and detached from the vehicle while driving, exactly as described in the recall, Lippert and Thor Motor Coach claim that this vehicle is not included in the recall by date of manufacture …

Look up ODI 11606268 at NHTSA ↗

THIS VEHICLE CONTAINS A BI-DIRECTIONAL RELAY (BIRD) WHICH INTERCONNECTS THE HOUSE AND VEHICLE BATTERIES FOR CHARGING VIA SHORE POWER, GENERATOR, OR ENGINE ALTERNATOR (WHILE DRIVING, OF COURSE) AND FOR THE AUX START FUNCTION IN CASE THE ENGINE BATTERY IS DEAD. THIS RELAY (OR ITS CONTROL CIRCUIT) IS SUBJECT TO FAILURE. I AM ON MY THIRD IN LESS THAN 2 YEARS. THE MOST COMMON SYMPTOM IS LACK OF CHARGING ON THE HOUSE BATTERIES. HOWEVER, IT CAN ALSO LEAD TO A DEAD ENGINE BATTERY IF THAT BATTERY BECOMES DEPLETED WHILE PARKED EVEN THOUGH CONNECTED T…

Look up ODI 10991973 at NHTSA ↗

IN THE THOR MOTOR COACH TUSCANY 38SQ THE BATTERIES ARE STORED IN A BOX THAT IS ONLY ACCESSIBLE FROM WITHIN THE MOTORHOME. IT IS IN THE SLEEPING AREA. GASES FROM THE BATTERIES THAT ARE NOT SEALED CAN ESCAPE TO THE INTERIOR OF THE SLEEPING AREA AND ARE A SAFETY HAZARD FOR THE OCCUPANTS.

Look up ODI 10981508 at NHTSA ↗

Right tag axle hub cap broke lose from the bracket securing the hub cap to the hub and departed the motorhome chassis. Incident occurred while traveling east on I-10 in Texas somewhere between San Antonio and Weimer. The hub cap bracket separated at the feet of the bracket. The feet of the bracket where still attached to the hub. Picture attached. The feet are available for further inspection. There were no warnings/symptoms when the incident occurred. Exactly when the event occurred is unknown. The hub cap assembly weighs approximatel…

Look up ODI 11437965 at NHTSA ↗

Windows have detached from the vehicle while driving on two occasions. One was recovered on the shoulder of the highway, another quite large window was lost on the interstate and could have hit another vehicle. The Lippert windows are already the subject of a NHTSA safety recall (21V-522); however, even though the windows have experienced an adhesive failure and detached from the vehicle while driving, exactly as described in the recall, Lippert and Thor Motor Coach claim that this vehicle is not included in the recall by date of manufacture …

Look up ODI 11606268 at NHTSA ↗

I was advised by my Cummins Service Center that the outer glass of double pane hung windows are at risk of falling out while driving. Evidently the glue bonding the two pieces of glass has failed. It’s happening on multiple windows. Evidently this was addressed for some newer models. The windows are made by Hehr which I believe is now owned by Lippert Industries. I feel like this should be a mandatory recall due to its possibility of falling out or off, going airborne like a missile and causing an accident. I noticed this happening before but…

Look up ODI 11535912 at NHTSA ↗

DOOR LOCK FAILED. I WAS LOCKED IN MY RV. DOOR WOULD NOT OPEN FROM INSDE OR OUTSIDE.

Look up ODI 11230464 at NHTSA ↗

SINCE MY ORIGINAL PURCHASE I HAVE HAD FOUR OCCURRENCES WHERE MY WIPERS QUIT WORKING IN MID STROKE WHILE TRAVELING ON THE INTERSTATE IN A STEADY RAIN. FAILURES OCCURRED AFTER THE WIPERS FUNCTIONED FOR OVER ONE HOUR AND ONLY WHEN OPERATING IN CONTINUOUS MODE. I WAS ASSURED BY THOR ON THE THREE PREVIOUS FAILURES THE PROBLEM HAD BEEN RESOLVED AND I WOULD NO LONGER HAVE ANY ISSUES. ON 1/3/2016 THE WIPER ONCE AGAIN FAILED WITH THE EXACT SAME SYMPTOMS AND THOR WILL NOT FIX THE PROBLEM CORRECTLY BECAUSE THEY SAY THE UNIT IS OUTSIDE OF THE WARRANTY N…

Look up ODI 10817521 at NHTSA ↗

The contact owns a 2020 Thor Tuscany RV built on a 2019 Freightliner chassis. The contact stated that while operating the RV, it was discovered that the front windshield wipers and cruise control were inoperable. The RV was taken to the local service center who diagnosed that the steering wheel control module was faulty and needed to be replaced; however, the part was not available. The RV was not repaired. The manufacturer was contacted but no assistance was offered. The failure mileage was 5,000. The contact stated that the required parts wi…

Look up ODI 11504923 at NHTSA ↗

THE MOTORHOME HAS GOODYEAR 275/70R22.5 G670 RV TIRES ON IT.I HAD A DOUBLE BLOW OUT ON THE REAR WITH THE TREAD COMING OFF BOTH TIRES.THE TIRES HAD NEW TREAD WITH 12000 MILES ON THEM.THE TIRE PRESSURE WAS CORRECT FOR THE WEIGHT AND A MONITORING SYSTEM WAS INSTALLED.WEATHER WAS UNDER 70 DEGREES SPEED ABOUT 60.GOODYEAR SAID THEY WOULD WARRANTY THEM BUT DIDN'T.MY CONCERN IS I HAVE 4 OTHER TIRES THE SAME ON THE MOTORHOME.I NEED TO FIND OUT WHY.CAN YOU DIRECT ME TO SOMEONE WITH THE EXPERTISE TO INSPECT THE TIRES.THANK YOU [XXX] I HAVE PICTURES ON C…

Look up ODI 10808938 at NHTSA ↗

Right tag axle hub cap broke lose from the bracket securing the hub cap to the hub and departed the motorhome chassis. Incident occurred while traveling east on I-10 in Texas somewhere between San Antonio and Weimer. The hub cap bracket separated at the feet of the bracket. The feet of the bracket where still attached to the hub. Picture attached. The feet are available for further inspection. There were no warnings/symptoms when the incident occurred. Exactly when the event occurred is unknown. The hub cap assembly weighs approximatel…

Look up ODI 11437965 at NHTSA ↗

THE KIWKEE 34 SERIES STEP HAS THE RIVETS FALLING OFF LETTING THE STEPS FALL AND MOVE WHEN A PERSON ENTERS/EXITS THE MOTORHOME. I HAVE TEMPORARILY SUPPORTED THE STEP WITH A RIVET HOWEVER IT IS CURRENTLY NOT BRADED AND IS HELD IN PLACE WITH JB WELD. I STEPPED OUT OF THE MOTORHOME AND THE STEP GAVE WAY AND I KEEP FROM FALLING BY HANGING ON TO THE HANDLE. THIS HAPPENED AFTER WE PARKED IN THE RV PARK FOR THE EVENING. IT APPEARS THAT THE RIVETS ARE TURNING CAUSING THE EXPANDED AREA TO GRIND OFF LETTING THE RIVETS TO WORK OUT. A PERSON CAN UNKNO…

Look up ODI 11099355 at NHTSA ↗

WHILE STATIONARY AND ENGINE COOL, I STARTED THE MOTOR COACH AND WHEN I STEPPED OUTSIDE I NOTICED THE SMELL OF DIESEL FUEL. UPON INVESTIGATION, IT WAS REVEALED THAT FLEETGUARD FUEL FILTER (RESIN CONSTRUCTION) MODEL FF63009 HAD A HAIR LINE CRACK IN THE SIDE OF THE HOUSING. A FINE SPRAY OF RAW FUEL WAS SPRAYING DIRECTLY ONTO THE DIESEL PARTICULATE FILTER (DPF). THE DPF WHEN IN REGENERATION MODE CAN REACH TEMPERATURES OF UP TO 500 DEGREE F. FORTUNATELY, THE EXHAUST SYSTEM WAS COLD AT START UP, BUT HAD IT BEEN IN RUNNING FOR A WHILE AND WENT INTO I…

Look up ODI 11233304 at NHTSA ↗