Thinking about buying an RV? Before you hit the road in your home-on-wheels, you should know which manufacturers tend to rack up the most complaints. After analyzing data from consumer reports, government agencies, and owner feedback, a clear pattern emerges – and it might change how you shop for your next recreational vehicle.
Forest River Leads the Pack in RV Complaints
When it comes to RV complaints, Forest River consistently tops the list. This isn’t just subjective opinion – the numbers tell a compelling story:
- 673 recalls filed with the National Highway Traffic Safety Administration (NHTSA) since 1996, ranking 18th among all vehicle manufacturers
- Averages approximately 50 recalls per year between 2015-2024
- 240 Better Business Bureau complaints over a three-year period (compared to just 88 for Thor Motor Coach and 38 for Winnebago)
- Consumer complaint rate is more than three times higher than Thor Industries when adjusted for market share
The most alarming Forest River recall involved their Cedar Creek and Puma fifth wheels, affecting over 41,000 units due to wiring fire risks in models spanning from 2004 to 2024. This massive recall highlights serious safety concerns that RV owners should be aware of.
Common Forest River complaints include:
- Water leaks
- Slide-out failures
- Electrical problems
- Structural issues requiring extensive repairs
Despite these issues, Forest River has managed to win dealer satisfaction awards for certain product lines, showing a disconnect between dealer and consumer perspectives.
Thor Industries: Quality Issues Across Multiple Brands
While Thor Industries has fewer absolute complaints than Forest River, it presents a more complex picture due to its vast brand portfolio. Thor owns numerous RV manufacturers, and the collective complaint data is concerning:
- Poor consumer rating of 1.7 out of 5 stars on PissedConsumer based on 362 reviews
- Thor’s collective family of brands has accumulated over 700 recalls across all their subsidiary companies
- For fifth wheels alone, Thor Industries subsidiaries account for 704 recalls, significantly higher than competitors
Notable Thor subsidiaries with quality concerns include:
| Thor Subsidiary | NHTSA Recalls | Common Issues |
|---|---|---|
| Jayco | 508 | Declining build quality since Thor acquisition |
| Keystone RV | 487 | Electronic control panel failures, cabinet issues |
| Thor Motor Coach | Numerous | Hurricane line known for poor construction |
Many customers specifically report that quality has declined following Thor’s acquisitions of previously reputable manufacturers. The Jayco Eagle model alone has triggered 103 separate recall campaigns, making it one of the most problematic individual RV models.
The RV Industry’s Systemic Quality Problems
What’s particularly concerning is that quality issues extend far beyond just Forest River and Thor. The data reveals an industry-wide problem affecting virtually all major manufacturers:
- Winnebago: Despite its established reputation, has 614 NHTSA recalls and faces ongoing complaints about plumbing system leaks
- Tiffin Motorhomes: Often considered premium, has some of the highest recall numbers among luxury RV manufacturers
- Gulf Stream Coach: 324 recalls with consistent complaints about water leakage and failing appliances
Root Causes of Poor RV Quality
The industry’s manufacturing practices contribute significantly to these quality issues:
- Piece-rate labor system: Most RVs are built by hand in factories concentrated around Elkhart, Indiana, where workers are often paid by piece rate rather than hourly wages. This incentivizes speed over thoroughness, leading to manufacturing errors.
- Production pressure: The industry’s focus on high volume manufacturing and competitive pricing creates an environment where quality control takes a backseat.
- Rapid model changes: Manufacturers frequently update designs without adequate testing, resulting in first-generation problems.
The Real Impact on RV Owners
These quality issues create significant problems for consumers that go beyond mere inconvenience:
Safety Concerns
Many complaints involve safety-critical systems:
- Braking system failures
- Electrical wiring creating fire risks
- Propane system defects
- Structural failures making RVs unsafe to operate
Financial Hardship
Quality problems often lead to substantial costs for owners:
- Thousands spent on repairs for brand-new units
- Extended warranty disputes
- Significant depreciation of defective RVs
- Lost vacation time while RVs undergo repairs
Many owners report their RVs spend more time in repair facilities than being used for recreation. Adding insult to injury, several manufacturers have been accused of using non-disclosure agreements to silence customers who receive buybacks or major repairs, potentially hiding the extent of quality problems.
Recent Industry Trends
The RV industry has faced increased scrutiny as quality issues have become more visible through social media and investigative journalism:
- The Wall Street Journal investigation into Forest River revealed concerning patterns of quality control issues
- RV shipments dropped 15.1% in May 2025 compared to the previous year, suggesting consumers may be becoming more cautious
- Class-action lawsuits have emerged against major manufacturers, including Winnebago’s Grand Design subsidiary for alleged catastrophic frame failures
Smart Shopping Strategies for Prospective RV Buyers
Given the widespread quality issues, how can you protect yourself when shopping for an RV?
Research Specific Models, Not Just Brands
Don’t rely solely on brand reputation – quality can vary significantly even within a single manufacturer’s product line:
- Use the NHTSA website’s searchable recall database to research specific RV models
- Check owner forums for common problems with specific floor plans and model years
- Look at the history of specific model lines rather than just the manufacturer name
Hire an Independent Inspector
Industry experts strongly recommend hiring independent inspectors even for brand-new RVs:
- A thorough pre-purchase inspection is essential regardless of manufacturer reputation
- Look for inspectors with NRVIA (National RV Inspectors Association) certification
- Expect to pay $400-800 for a comprehensive inspection – money well spent considering the potential repair costs
Consider Extended Warranty Protection
For those purchasing RVs from manufacturers with high complaint volumes:
- Extended warranties become particularly important financial protections
- Gap insurance can protect you if your RV becomes a total loss
- Carefully review warranty terms, as many exclude common failure points
Visit Owner Forums and Social Media Groups
Join RV owner communities before making a purchase:
- Facebook groups dedicated to specific RV brands or models
- RV forums where owners share real-world experiences
- YouTube channels with detailed RV reviews and repair stories
Key Takeaways About RV Manufacturer Complaints
The data clearly shows Forest River leads the industry in complaint volume, with Thor Industries following closely behind. However, the most important lesson is that quality issues plague the entire RV industry.
The concentration of manufacturing in specific geographic areas with piece-rate labor, combined with price competition and rapid production schedules, has created an industry-wide quality crisis. Until fundamental manufacturing practices change, consumers should expect to encounter significant quality issues regardless of which manufacturer they choose.
Your best protection is thorough research, professional inspections, and realistic expectations about the need for repairs – even with brand new units. While no RV manufacturer is perfect, understanding which ones have the most complaints can help you make a more informed decision for your RV lifestyle.
