2018 Thor Motor Coach Palazzo Recalls & Complaints

Incident: June 27, 2025 · Filed: July 2, 2025

The Thor motorhome has several windows. The windows they installed are laminated windows, with two panes of glass and a seal or glue which connects the outer glass to the inner glass. The attachment method for the outer glass is ineffective. As a result, the outer glass pane comes loose from the inner and is prone to fall off or fly off at highway speeds. The risk is that the pane could strike another vehicle and possibly cause an accident. Already Thor has replaced two of the window units on this unit around 2021, not under warranty but as a customer courtesy. I now have a third window unit that is experiencing the same problem. It is apparent to me Thor has acknowledged there is a risk present when they replaced the other units. In addition, Thor has issued a recall for several year models after my year model. It seems clear they are aware there is a risk of window failure in model years outside of the recall. Unfortunately, they are unwilling to address the risk and hazard.

Incident: June 3, 2024 · Filed: November 8, 2024

MY 2018 THOR PALAZZO DRIVERSIDE AND PASSENGER SIDE WINDOWS HAVE FOGGED UP TO WHERE IT IS VERY HARD TO SEE OUT OF AND HAS BECOME A SAFETY CONCERN.

Incident: June 30, 2024 · Filed: July 4, 2024

Hello NTSB, the frameless windows Thor used on my rv are all failing.. basically the adhesive used to glue the bottom rail onto the glass keeps failing. This week I had two windows fail. The top bunk window, and the emergency exit window. Both window (at separate times) failed while driving. Lucky I saw them break loose and my wife was able to grab the window before it flew off on the freeway and possibly caused a major accident or injury with flying glass at freeway speed. Again this is the 4th window failure in the last 3 years. All with the Same problem. Last summer I had the same problem with the bottom bunk window, however that window flew off somewhere in New Mexico. Unfortunately I have no idea if the large piece of glass flying off my rv at freeway speed hurt anyone or anything. I filed a NTSB report (just like this) last year, and the never received or heard anything back from you guys. A year later 2 more windows have failed. Reading other post in the palazzo Facebook page, window failure (as I’m describing) is a very common occurrence. So much so, the 2017 and 2016 units have the recall on the windows. However the 2018’s are not included in that recall, but are obviously having the same problem. Please investigate this. Thor and the windows manufacturer HELM, are aware of the problem. So much so they sent me a new window and frame for the one I lost at no cost. Taking with HELM, they said they see this a lot.

Incident: June 5, 2024 · Filed: June 12, 2024

The LP gas line running to the rear mounted water heater started leaking and when removed you see where the hose was burned due to faulty engineering of hanger supports or improper installation. I have the current hose and have pictures of the engine compartment and the burned hose. No insurance claim or manufacturer contact was initiated. If you were to drive with the LP system energized and fire or explosion could occur with propane leaking into the engine compartment. The LP leak system did not detect the leak as it is located in the living area by the stove. A secondary sensor in now being installed in the sleeping area which is right next to the area where the hose was installed. The only warning was our ability to smell the propane and shut the tank operating valve.

Incident: April 26, 2024 · Filed: May 1, 2024

Recall 21-E-047 was a recall on HERH window assemblies. The window adhesion is faulty and causes the window to separate from the vent bracket. I experienced this with my Palazzo. While traveling this last weekend a window broke free and came close to smashing into the car behind me. An absolute nightmare. Not only a major distraction to the RV driver but a potential fatal hazard if the window smashes into a trailing drivers windshield. I contacted lippert and sent photos and VIN. I was advised my coach VIN didn't fit within the VIN sequence they identified. Therefore they take no responsibility for the faulty part. This seems erroneous. If I supply the same evidence of the issue prompting the recall and the part is an OEM assembly I would expect they would be obligated to fix. This is a major safety issue.

Incident: April 15, 2021 · Filed: January 29, 2024

The contact owns a 2018 Thor Palazzo. The contact stated that while driving at an undisclosed speed, through the sideview mirror, he observed movement of the driver's side awning window, prompting him to pull to the shoulder of the roadway. After a visual inspection, he observed that the glass panel within the awning window was detached. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 20V339000 (Visibility), but the VIN was not included. The manufacturer was notified of the failure but provided no assistance. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 15,000.

Incident: November 8, 2023 · Filed: November 9, 2023

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.

Incident: June 16, 2023 · Filed: August 18, 2023

The coach windows on the RV keep failing. Last year I had two windows fail on my drive to Wyoming. The sealant that hold the window bracket comes detached from the glass widow. When that happens the window flaps is the wind and if the window swing higher than 45 degrees, the window can slide off the top rail, and become a projectile for anyone traveling behind me. Since my windows didn’t fall off, I bought new sealant and reattached the rails back to my glass. Those two windows have been good since. Then this summer I lost and different body window (lower bunk). But this time, the window just flew off without me noticing. I sure hope it didn’t cause an accident or injury anyone. Lippert is the manufacturer of the window. And they have a recall on them, however the recall ends 2 month before my unit was built. So they say I don’t qualify for the recall. However I have had 3 windows fail for the sale reason and cause as the recall that ends 2 month before my unit was built. The recall window obviously needs to be expanded as many more units are effected. Talking with other owners of the same model on my Facebook group, this is a know problem. With a lot of failures. Someone is going to get injured when a window falls on the road and causes a accident or possibly even death.

Incident: April 5, 2022 · Filed: May 21, 2022

floor of storage area is failing this could cause items in storage to fall out while driving. the items that fall out could be hit by the tires of the motorhome or hit another vehicle causing a serious accident.

Incident: May 15, 2021 · Filed: June 3, 2021

The Hehr-Lippert windows installed on this Thor motorhome have a design flaw where the adhesive between the outer glass and mounting frame becomes weak when expose to the sun/heat and can fly off the coach at speed and become a trajectory. The Hehr-Lippert side windows installed on this Thor motorhome in the driver and passenger areas can fog between the glass causing poor side and mirror visibility.