2019 THOR MOTOR COACH ACE — Problems, Recalls & Safety Data

TWO OF THE FOUR WELDS ON THE MOUNTING BRACKETS HAVE BROKEN AND ARE COMPLETELY SEPARATED .THE TANK CAN ACTUALLY SWAY A FEW DEGREES. VEHICLE IS UNSAFE TO MOVE AS TANK IS COMPLETELY FULL. WIRES HAVE BEEN ROUTED BETWEEN AND THROUGH THE BRACKETS MULTIPLYING THE DANGER AND PROBLEM. THIS SITUATION OF ROUTING AND SUSPENDING WIRES IS COVERED IN ANOTHER ISSUE NHTSA #11289727. THIS TYPE OF SAFETY PROBLEM SEEMS ENDEMIC OF THIS MOTORHOME AND IT'S CONSTRUCTION. THIS STRETCHES CREDIBILITY TO THINK THIS IS A SINGLE UNIT ISSUE. IT IS IMPOSSIBLE TO KNOW WHEN THIS OCCURRED. THE TANK IS MANUFACTURED BY MANCHESTER TANKS AND CARRIES SERIAL #1898870 *DT*JB *DT *TP *DT MANUFACTURE HAS BEEN CONTACTED AND TANK HAS BEEN REPLACED.*JB

TWO OF THE FOUR WELDS ON THE MOUNTING BRACKETS HAVE BROKEN AND ARE COMPLETELY SEPARATED .THE TANK CAN ACTUALLY SWAY A FEW DEGREES. VEHICLE IS UNSAFE TO MOVE AS TANK IS COMPLETELY FULL. WIRES HAVE BEEN ROUTED BETWEEN AND THROUGH THE BRACKETS MULTIPLYING THE DANGER AND PROBLEM. THIS SITUATION OF ROUTING AND SUSPENDING WIRES IS COVERED IN ANOTHER ISSUE NHTSA #11289727. THIS TYPE OF SAFETY PROBLEM SEEMS ENDEMIC OF THIS MOTORHOME AND IT'S CONSTRUCTION. THIS STRETCHES CREDIBILITY TO THINK THIS IS A SINGLE UNIT ISSUE. IT IS IMPOSSIBLE TO KNOW WHEN THIS OCCURRED. THE TANK IS MANUFACTURED BY MANCHESTER TANKS AND CARRIES SERIAL #1898870 *DT*JB *DT *TP *DT MANUFACTURE HAS BEEN CONTACTED AND TANK HAS BEEN REPLACED.*JB

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 THIS OCCURRED THE VEHICLE WAS BELIEVED TO BE IN MOTION AND THE WIND MOST LIKELY PREVENTED A CONTINUAL FIRE AS THE VEHICLE WAS TRAVELING ON THE INTERSTATE. CURRENT FROM THE HOUSE BATTERIES WOULD HAVE BEEN SUPPLEMENTED BY CURRENT FROM THE ENGINE ALTERNATOR AND BATTERY WHICH ARE ALL CONNECTED TOGETHER THOROUGH AN ISOLATION RELAY WHEN THE ENGINE IS RUNNING. NO MAJOR FIRE OCCURRED BUT SEVERAL COMPONENTS NEEDED TO BE REPLACED ALONG WITH ALL BATTERIES. DURING REPAIR A HYDRAULIC LINE WAS FOUND DRAPED ON THE CATALYTIC CONVERTER AND WAS ALMOST BURNED THROUGH. ATTACHED PHOTOS SHOW THE RESULT.

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 THIS OCCURRED THE VEHICLE WAS BELIEVED TO BE IN MOTION AND THE WIND MOST LIKELY PREVENTED A CONTINUAL FIRE AS THE VEHICLE WAS TRAVELING ON THE INTERSTATE. CURRENT FROM THE HOUSE BATTERIES WOULD HAVE BEEN SUPPLEMENTED BY CURRENT FROM THE ENGINE ALTERNATOR AND BATTERY WHICH ARE ALL CONNECTED TOGETHER THOROUGH AN ISOLATION RELAY WHEN THE ENGINE IS RUNNING. NO MAJOR FIRE OCCURRED BUT SEVERAL COMPONENTS NEEDED TO BE REPLACED ALONG WITH ALL BATTERIES. DURING REPAIR A HYDRAULIC LINE WAS FOUND DRAPED ON THE CATALYTIC CONVERTER AND WAS ALMOST BURNED THROUGH. ATTACHED PHOTOS SHOW THE RESULT.

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 THIS OCCURRED THE VEHICLE WAS BELIEVED TO BE IN MOTION AND THE WIND MOST LIKELY PREVENTED A CONTINUAL FIRE AS THE VEHICLE WAS TRAVELING ON THE INTERSTATE. CURRENT FROM THE HOUSE BATTERIES WOULD HAVE BEEN SUPPLEMENTED BY CURRENT FROM THE ENGINE ALTERNATOR AND BATTERY WHICH ARE ALL CONNECTED TOGETHER THOROUGH AN ISOLATION RELAY WHEN THE ENGINE IS RUNNING. NO MAJOR FIRE OCCURRED BUT SEVERAL COMPONENTS NEEDED TO BE REPLACED ALONG WITH ALL BATTERIES. DURING REPAIR A HYDRAULIC LINE WAS FOUND DRAPED ON THE CATALYTIC CONVERTER AND WAS ALMOST BURNED THROUGH. ATTACHED PHOTOS SHOW THE RESULT.