Thor Motor Coach-Astoria RV Exposed: Leaks, Slide Failures, Costly Repairs & Service Delays

Introduction and Model Background

AI-powered research tools have systematically collected and analyzed public information to produce this report. The Thor Motor Coach Astoria refers to a diesel-pusher Class A motorhome originally developed under the Damon brand and later under Thor Motor Coach after Thor acquired Damon. Most Astoria units in the market today are used models from roughly the late 2000s to early 2010s, commonly built on Freightliner chassis with Cummins engines. Note: Do not confuse this coach with the Dutchmen “Astoria” towable line (a separate Thor Industries subsidiary). This report focuses on the Thor Motor Coach Astoria diesel motorhome and owner-reported experiences tied to that platform.

Overall reputation in the RV community is mixed-to-negative for this era of Thor-branded diesel pushers, with repeat patterns of water intrusion, slide-out and hydraulic jack issues, electrical gremlins, and time-consuming service delays. While many owners praise the floorplans and the Freightliner/Cummins backbone, a consistent stream of complaints suggests costly ownership risks if you acquire one without a rigorous pre-purchase inspection and a realistic maintenance budget.

Where to Find Unfiltered Owner Feedback and Evidence

To verify, expand, or challenge any claim in this report, consult multiple public sources. Use these searches and forums to read firsthand accounts and check for updates:

• Google search: Thor Motor Coach Astoria Problems
• YouTube search: Thor Motor Coach Astoria Problems (watch owner walk-throughs and breakdowns)
• Better Business Bureau search: Thor Motor Coach Astoria (company-level complaint patterns)
• Reddit r/rvs: Thor Motor Coach Astoria Problems
• Reddit r/GoRVing: Thor Motor Coach Astoria Problems
• Reddit r/RVLiving: Thor Motor Coach Astoria Problems
• RVInsider reviews: Thor Motor Coach Astoria Problems
• Good Sam Community: Thor Motor Coach Astoria Problems
• NHTSA Recalls database: Thor Motor Coach Astoria (check by VIN to be precise)
• Forums with onsite search: RVForums.com, RVForum.net, RVUSA Forum (search “Thor Motor Coach Astoria Problems”)
• Google search for Facebook owner groups: Thor Motor Coach Astoria (join multiple groups for unfiltered owner narratives)
• PissedConsumer main page (use the site’s search bar for “Thor Motor Coach Astoria” and “Thor Motor Coach”)

We also recommend watching investigative consumer creators who expose systemic RV quality issues. See Liz Amazing’s investigations into RV quality, then search her channel for the specific model you’re considering.

Have you owned this coach? Add your Astoria ownership lessons for other shoppers.

Before You Buy: A Third-Party RV Inspection Is Your Only Leverage

Multiple owner accounts describe months-long repair waits after taking delivery, cancelled camping trips, and warranty ping-pong between dealers, chassis shops, and component manufacturers. Your strongest leverage is before you sign. Hire an independent NRVIA-certified or highly experienced inspector who understands diesel pushers of this era. A robust inspection typically includes roof membrane and sealant testing, moisture meter readings in walls and slide floors, thermal imaging for hidden leaks, chassis and suspension evaluation, generator load testing, electrical system amperage/voltage checks, and appliance performance.

Use this to locate a professional: Search: RV Inspectors near me. If a dealer balks at allowing a thorough inspection, treat that as a red flag and walk.

Headline Problems Reported by Thor Motor Coach Astoria Owners

Water Intrusion, Delamination, and Roof/Cap Seams

Repeated consumer reports point to water intrusion at roof-to-cap seams, slide headers, and window frames. Over time, moisture can lead to soft spots, wall delamination (bubbling or rippling fiberglass), swollen cabinetry, and mold. Buyers often discover issues only after the first heavy rain. Several owners describe pulling off trim to find saturated wood under the roof membrane or behind the front cap. Verifiable patterns of water damage for this model/era appear in forum threads and video walkthroughs: Google: Thor Motor Coach Astoria Water Damage, and broader complaints aggregations: YouTube: Thor Motor Coach Astoria Problems.

• Common indicators: Musty odor, spongy slide floors, discolored ceiling panels, fogged windows with water streaks, peeling wall vinyl.
• Cost exposure: Slide floor rebuilds can run $2,000–$6,000+, roof membrane replacement $8,000–$15,000 depending on extent of substrate rot.
• See crowd-sourced defect coverage to cross-check expectations: consumer-focused RV defect coverage by Liz Amazing.

Before closing, insist your inspector conduct moisture mapping and probe all slide corners. If you own one already, document damage promptly and check whether past recalls or service bulletins applied to your VIN. Also review public forums: Good Sam: Thor Motor Coach Astoria Water Damage.

Slide-Out Mechanisms and Floor Rot

Owners report binding, racking, and motor failures in slide-outs after years of use, sometimes following undetected leaks. On some Astoria floorplans, saturated slide floors decay from the inside out, increasing drag and causing alignment issues. Reports reference shimming slides, replacing rollers, and motor or controller failures, sometimes compounded by blown fuses and voltage drop. Search community evidence here: Google: Thor Motor Coach Astoria Slide Out Problems and RVInsider: Thor Motor Coach Astoria Problems.

• Symptoms: Slides move unevenly, stop mid-travel, blow fuses, or require manual assist to retract.
• Risks: Operating a misaligned slide can shear fasteners or damage floor structure, escalating repair costs.
• Inspection tip: Run each slide multiple times on shore power and generator; listen for binding and watch for slow/uneven travel.

Hydraulic Leveling Jacks (Leaks and Failures)

Hydraulic jack systems on coaches of this vintage frequently leak at fittings or seals, “slow bleed” down overnight, or fail to retract without manual intervention. Owners describe replacing hoses and entire pump assemblies, sometimes after fluid contamination. Jack failures can immobilize the coach at a campsite or dealer lot. For case examples and troubleshooting, see: Reddit r/rvs: Thor Motor Coach Astoria Problems and Good Sam: Thor Motor Coach Astoria Hydraulic Jacks.

Electrical System Gremlins and Power Distribution

Electrical complaints range from intermittent 12V failures and parasitic draws to transfer switch arcing and inverter/charger faults. Some owners report balcony lights toggling randomly, GFCI nuisance trips, or malfunctioning step covers. In older diesel pushers, battery control centers and aging crimp connectors are repeat culprits. Owners often replace the transfer switch proactively due to heat damage. Evidence sources: Google: Thor Motor Coach Astoria Electrical Problems, and the forum ecosystem (use onsite search): RVForums.com, RVForum.net, RVUSA Forum.

• Diagnosis note: A full-load test of inverter/charger and transfer switch under generator and shore power is essential before purchase.
• Battery health: Old house batteries mask voltage issues; load-test all batteries and inspect cables for corrosion.

Chassis and Drivetrain: Freightliner/Cummins Era-Specific Issues

Because Astoria units are older, chassis-related age and mileage factors dominate risk. Owners report exhaust leaks, turbo actuator faults, coolant hose deterioration, and radiator/charge-air-cooler issues. On emissions-equipped model years, EGR and aftertreatment components (DOC/DPF/DEF for later units) can trigger derates or limp-mode events. Steering components and airbags age out; ride degradation and wander are common complaints until suspension bushings, shocks, and alignment are refreshed. See relevant recall and chassis checks by VIN: NHTSA recalls: Thor Motor Coach Astoria and community reports: Google: Thor Motor Coach Astoria Chassis Problems.

• Heat management: Inspect for clogged coolers, fan hub wear, and signs of overheating. Ask for service records on coolant and transmission fluid changes.
• Brakes and air system: Age-related leaks in air lines, dryer cartridges overdue, aging brake components; test build time and leak-down.
• Financial exposure: Major chassis repairs (aftertreatment, turbo, radiator) can exceed $5,000–$12,000+ quickly.

If you have encountered emission- or cooling-related warnings on an Astoria, share what failed and how it was fixed so other shoppers understand potential scope.

Braking, Steering, and Recall Awareness

Public records show periodic recalls across Freightliner-based motorhomes for items such as brake light module faults, steering gear concerns, and power steering hose routing—recalls may not name Astoria specifically unless the VIN ties in. Always run the VIN: NHTSA Recalls: Thor Motor Coach Astoria (use VIN). Owners who purchased used units report discovering open recalls years later. If a recall remedy was delayed or poorly executed, document it and escalate through the chassis manufacturer and NHTSA.

Onan Generator Problems (Hard Starts, Fuel, Control Boards)

Onan Quiet Diesel generators on older diesel pushers can develop hard-start and surging issues related to fuel lift pumps, clogged filters, or aging control boards. Some owners report surging under AC load and shutdowns at higher temperatures. Verify generator hours and perform a load test with both air conditioners running. See owner narratives via: YouTube: Thor Motor Coach Astoria Generator Problems.

HVAC and Appliance Reliability

Roof AC units lose efficiency over time; blower motors, capacitors, and control boards are typical failure points. Norcold/Dometic refrigerator issues (ammonia leaks, cooling unit failures) and water heater ignition problems are also common. In several one-star owner reviews (brand-level), buyers describe replacing multiple appliances within the first season after purchase. Aggregated owner reports: RVInsider: Thor Motor Coach Astoria Complaints and Google: Thor Motor Coach Astoria Appliance Problems.

Interior Fit/Finish, Furniture Peeling, and Exterior Paint Checking

Reports include delaminating cabinet faces, squeaks/creaks, and “pleather” furniture peeling on aging units. Another known issue for mid/late-2000s full-body paint coaches is paint or clearcoat checking/crazing, especially on darker colors under UV exposure—an extremely expensive cosmetic problem to remedy. Threads and photo evidence show cracks resembling alligator skin on caps and sidewalls. Related owner discussions: Google: Thor Motor Coach Astoria Paint Checking.

Weight Ratings, Tires, and Load Management

Some owners underestimate how close these coaches can be to axle or tire limits when fully loaded. Aging tires (“China bomb” discussions are common across RVs generally) and underinflation increase blowout risk. A front-tire blowout on a diesel pusher can be catastrophic. Weigh the coach on all four corners, set tire pressures per load tables, and confirm DOT tire dates. Community safety advice is widespread: Reddit r/GoRVing: Thor Motor Coach Astoria Tire Blowout and Good Sam: Thor Motor Coach Astoria Tire Issues.

Customer Service, Warranty Denials, and Parts Delays

Although most Astoria coaches are well out of factory warranty, it’s important to study brand-level patterns. Numerous owners recount long waits for parts, finger-pointing between Thor Motor Coach, the chassis maker, and component suppliers, and dealers prioritizing new sales over service appointments. Time-to-repair measured in months is not unusual in peak seasons. Investigate brand-level complaint patterns: BBB: Thor Motor Coach Astoria, Google: Thor Motor Coach Astoria Complaints, and long-form owner stories on YouTube: Thor Motor Coach Astoria Issues.

For a broader industry lens on service bottlenecks and quality control trends, investigate creators who document real owner experiences, such as Liz Amazing’s channel. Then search her videos for your specific model before you buy.

Recalls and Official Actions

Always run the VIN for your exact unit in the NHTSA database: NHTSA Recalls: Thor Motor Coach Astoria. Note that chassis-related recalls may be filed under Freightliner or component vendors rather than Thor Motor Coach. If a recall is open, schedule service immediately—recall remedies are no-cost, but delays happen. Keep records of all communications and work orders.

Discuss recall experiences, including parts availability and dealer responsiveness, to guide other buyers: How fast was your recall fixed?

Legal and Regulatory Warnings

Owners have raised allegations across RV brands, including Thor Motor Coach, of warranty denials for defects they believe should have been covered, misrepresentations of features, and delays that impose significant consequential losses (missed trips, storage costs). Key legal frameworks to know:

• Magnuson-Moss Warranty Act (U.S.): Governs consumer product warranties. If a written warranty applied when you purchased (e.g., as a subsequent owner of a certified used vehicle or under extended service contracts), improper denials can trigger remedies including attorney’s fees.
• State “lemon law” and RV-specific statutes: Some states cover motorhomes under lemon laws; others limit coverage. Research your state’s definitions and deadlines; motorhomes often fall under different timelines than autos.
• FTC and state consumer protection statutes: Prohibit unfair or deceptive acts. Advertising claims about quality, inspections, and “like new” condition can be challenged if contradicted by evidence.
• NHTSA and safety defects: Report safety-related failures (steering, brakes, fire risk) to NHTSA to trigger investigations and recalls when warranted.

Document everything: dates, communications, photos, technician findings. If you believe you were misled, consult a consumer attorney familiar with RV cases. Public threads show how documentation makes or breaks claims: Reddit r/rvs: Thor Motor Coach Astoria Warranty Problems.

Product and Safety Impact Analysis

In aggregate, the reported defects materially affect both safety and financial risk for buyers of aging diesel pushers:

• Safety: Tire blowouts, brake/steering issues, or engine derates on grades pose real hazards. Water-damaged structures can impair slide integrity and exit routes. Electrical failures risk fire if transfer switches arc or wires overheat.
• Financial: Water intrusion and slide rebuilds, paint checking, and drivetrain/emissions repairs represent high four- to low five-figure exposures on a coach often purchased for under $100k in the used market. A single major repair can eclipse a significant portion of the purchase price.
• Time: Reports of multi-month service delays effectively sideline a coach for a whole season— eroding ownership value.

If you own or previously owned an Astoria, what repair surprised you most financially? Your data point helps future buyers plan.

What to Inspect and Verify on a Used Thor Motor Coach Astoria

Because these coaches are older and condition varies widely, a deep-dive inspection is non-negotiable. Hire an independent expert via RV Inspectors near me and require the seller’s cooperation.

• Roof and caps: Check all seams, ladder mounts, and roof penetrations; look for surface cracks, soft decking, and uneven sealant. Scan for moisture with a meter and thermal camera.
• Slides: Inspect slide floors above and below for softness, edge swelling, and water staining; run slides repeatedly and check for alignment.
• Exterior walls: Look for delamination bubbles or rippling; tap-test suspect areas. Examine around windows and awning mounts.
• Chassis: Pull chassis service records. Inspect suspension bushings, airbags, shocks, steering gear, and alignment. Scan ECM for fault codes.
• Tires and wheels: Check DOT dates and replace any tire older than ~6 years regardless of tread; weigh coach and set pressures accordingly.
• Electrical: Inspect transfer switch for heat damage; load test batteries; confirm correct charging and inverter output under real loads.
• Plumbing: Pressure test for leaks; inspect water pump, fittings, and water heater; look under sinks and behind shower for hidden moisture.
• Generator: Full load test for one hour; verify voltage stability and absence of surging. Check for leaks and proper maintenance intervals.
• HVAC and appliances: Test each AC on separate thermostat zones; verify refrigerator temps with thermometer; run furnace and oven.
• Body and paint: Examine for clearcoat checking or crazing, especially on dark caps; evaluate cost of repaint or live-with.
• Documentation: Confirm title status, VIN recall status, and any outstanding liens; review previous owner’s maintenance logs.

For a final pre-close sanity check, consider a second opinion: Find a local RV inspector.

Price, Value, and Depreciation Realities

Older diesel pushers can appear to be bargains, but the “catch-up” maintenance and remediation on an Astoria can easily equal 20–40% of the purchase price if multiple big-ticket items hit. Many shoppers underestimate the cost and difficulty of sourcing parts for legacy interiors and body components. Extended service contracts have mixed reviews; scrutinize exclusions and claim limits closely.

• Budget add-ons: Expect to invest in new tires, battery banks, suspension refresh, and resealing/roof work unless provably recent.
• Opportunity cost: A season without the coach due to service delays equates to lost use plus storage and insurance costs.
• Evidence sources: One-star narratives and cost breakdowns: Google: Thor Motor Coach Astoria Owner Reviews and YouTube: Thor Motor Coach Astoria complaints.

Where Owners Say Service Goes Wrong

Service complaints cluster around three pain points: diagnosis accuracy, parts logistics, and responsibility ping-pong between OEMs and component vendors. Examples include dealers misdiagnosing leaks as “normal condensation,” delays waiting on proprietary trim or slide parts, and out-of-pocket expenses for borderline warranty items. Aggregated experiences: BBB threads involving Thor Motor Coach Astoria and Google: Thor Motor Coach Astoria Service Delays.

Have you been stuck in the repair queue? Tell readers how long and what finally resolved it.

Balanced Notes: Strengths to Acknowledge

To maintain objectivity: many Astoria owners value the floorplans and storage, and the Freightliner/Cummins platform can be reliable with disciplined maintenance. Independent chassis shops are widespread, and parts for common diesel components remain available. Some owners report years of service after addressing initial leaks and refreshing wear components. You can find owner tips for preventative care in long-form threads: Good Sam: Thor Motor Coach Astoria Maintenance.

For broader industry advice from experienced RVers, consider creators who highlight pre-purchase due diligence, like Liz Amazing — search her channel for “Astoria” or your exact model name.

Action Plan for Buyers

• Research deeply: Read across multiple sources: Google: Thor Motor Coach Astoria Issues, Reddit r/RVLiving: Thor Motor Coach Astoria Problems, and RVInsider search results.
• Demand a full inspection: Use an independent expert: Find RV Inspectors near me and do not waive your right to a thorough test.
• Budget reserves: Hold 10–20% of the purchase price in reserve for immediate remediation; prioritize water intrusion, tires, brakes, and electrical safety.
• VIN checks: Confirm no open recalls via NHTSA.
• Community due diligence: Join multiple Facebook owner groups (find them via Google: Thor Motor Coach Astoria Facebook Groups) for day-to-day realities.

Citations and Where to Verify Specific Claims

• YouTube: Thor Motor Coach Astoria Problems — video evidence and owner diaries.
• Google: Thor Motor Coach Astoria Complaints — broad-based complaint aggregation.
• BBB: Thor Motor Coach Astoria — formal complaints and patterns.
• NHTSA Recalls: Thor Motor Coach Astoria — safety defects and remedies.
• Reddit r/rvs: Thor Motor Coach Astoria Problems — unfiltered troubleshooting threads.
• RVInsider: Thor Motor Coach Astoria Issues — owner review excerpts with star ratings.

Have something to add or correct? Post your evidence or documents in the comments so we can update shoppers.

Final Recommendation

Based on the concentration of owner-reported water intrusion, slide and hydraulic issues, electrical gremlins, aging chassis risks, and recurring service delays, we do not recommend the Thor Motor Coach Astoria for buyers who are not prepared for intensive due diligence and significant potential remediation costs. If you value reliability and lower total cost of ownership, consider alternative brands/models with stronger, recent owner satisfaction trends and verified service support.

Owner Discussion and Comments

Your real-world story matters. What failed, what did it cost, and how responsive were the dealer and OEM? Please include year, floorplan, mileage/hours, and repair documentation if you can. Your experiences will help other RV shoppers make informed decisions.