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Thor Tuscany Brake Failure
We picked up our 2015 Thor Tuscany in October. As it had a little over 2000 miles from the factory delivery trip and a couple of return trips to the dealer for warrantee repairs, we assumed the chassis would be able to handle a trip from California to Texas to visit family for Christmas. Brakes appeared to be operating relatively well, albeit a little touchy. We were 56 miles from our destination when the right rear inner tire sidewall violently blew. After finding a nearby tire repair facility, it was replaced and we finally arrived at our destination, although the brakes now were barely stopping the rig (they had been progressively worsening since the blowout). Freightliner Austin was booked solid for at least a week, and would not take us in for emergent repair, so Freightliner Direct sent out a local mobile repair person. He examined the brakes and believed they may have been dragging for some time (although we did not notice with the 450 HP Cummins). He also examined the brake shoes and drums and did not notice any heat damage, and thought the shoes looked OK. He adjusted the brakes and they appeared to be working, though not as well as before the blowout (they went from grabby to a bit mushy). After Christmas, we drove over to visit family north of Houston. When we prepared to return to the Austin area after the visit, we noticed the left rear inner tire had deflated off the rim and fluid was leaking from the seal down the tire. Another nearby tire repair facility replaced that tire, and we called Freightliner Houston for emergent repairs. Even though they have a 24/7 repair facility, they too were booked out at least a week and would not be able to help. Fortunately, a Freightliner repair facility in Bryan was able to check out our rig on New Year's Eve. Quick Assessment revealed that the brake system was shot and needed major repairs. After a couple of weeks of troubleshooting and part replacement, the root cause was finally diagnosed as a service brake adapter that was never properly lubricated at the factory (it was completely dry), causing the brakes to partially deploy during operation. I had to eventually abandon the DW in Texas, as I had to report to Japan for work. The RV is still sitting at the Freightliner repair facility, as they are waiting for front brake caliper assemblies to be manufactured by Daimler. Nobody at Freightliner Direct is able to tell us an estimated date when the final brake parts will be manufactured, so the DW is stuck in Texas waiting for parts.
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