While no RV brand is perfect, some have consistent patterns of quality issues, recall frequency, and customer service concerns that warrant extra caution from buyers. Forest River and Thor Industries subsidiaries (including Keystone) have faced significant criticism for manufacturing defects, build quality problems, and poor warranty support. The key is thorough research, careful inspection, and considering alternatives like renting first to test models before committing to a purchase.

Look, we've all heard the horror stories—brand new RVs with leaky roofs, electrical failures, and warranty nightmares that turn dream adventures into repair shop marathons. The truth is, not all RV brands are created equal, and some have earned reputations that should give any buyer pause.

But here's the thing: we're not here to bash anyone. Every manufacturer builds both gems and lemons, and even the "brands to avoid" lists have happy customers who'd swear by their rigs. What we're after is helping you make smart decisions with your hard-earned dollars.

Whether you're a first-time buyer doing your homework or a seasoned RVer looking to upgrade, this guide will walk you through the brands that consistently show up in complaint forums, recall databases, and warranty headache stories—plus what to look for instead.

Which RV Brands Have the Most Quality Issues in 2025?

Based on current recalls, customer reviews, and industry data, Forest River and Thor Industries subsidiaries show the highest frequency of quality control problems, manufacturing defects, and customer service complaints among major RV manufacturers.

Recent data tells a concerning story. According to a 2025 Wall Street Journal investigation, Forest River issued more recalls than any U.S. automaker or RV manufacturer from 2015 to 2024—many due to human manufacturing errors rather than faulty parts.

Forest River: Volume Over Quality

Forest River averages 50 recalls per year, often for preventable issues like incorrect fuse installations, misaligned furnace vents, and workers puncturing microwaves with improperly sized screws. Their compensation structure prioritizes quantity over quality, incentivizing employees to focus on production volume rather than careful craftsmanship.

Customer complaints are consistent: poor attention to detail, lack of quality control, and difficult warranty experiences. Many owners report spending more time at repair shops than enjoying their RVs.

Thor Industries Subsidiaries

Thor's acquisition strategy has led to quality inconsistencies across their portfolio. Keystone, once a solid brand pre-2001, has particularly struggled since the Thor takeover. Common complaints include:

• Keystone RVs: Electronics that malfunction, sensors that give false readings, pressboard cabinets that fall apart under travel stress
• Thor Hurricane: Consistent poor reviews for quality control and parts failures
• Four Winds: Customer complaints about poor workmanship, low-quality materials, and inadequate service

What Are the Most Common Problems with These Brands?

The most frequently reported issues include delamination of walls and roofing, electrical system failures, water intrusion from poor sealing, cabinetry that loosens or falls apart, and appliances that fail prematurely or arrive damaged from the factory.

Here's what keeps popping up in owner forums and service records:

Structural and Build Quality Issues

• Delamination: Exterior siding separating from walls, creating that telltale "wavy" appearance
• Water intrusion: Poor roof seals, window leaks, and slide-out problems
• Floor problems: Soft spots from water damage, swelling underlayment

Electrical and Mechanical Problems

• Wiring issues: Improper installations, fire hazards from incorrect fusing
• Appliance failures: Microwaves damaged during installation, furnace problems
• Slide-out malfunctions: Motors failing, alignment issues, seal problems

Fit and Finish Concerns

• Cabinet quality: Pressboard with thin veneers that don't hold up to travel vibration
• Trim work: Pieces falling off, poor attachment methods
• Door and hardware issues: Components that fail or work poorly from day one

The most frustrating part? Many of these issues appear within the first few months of ownership, suggesting they could have been caught with better quality control.

Are There Better RV Brand Alternatives to Consider?

Yes—several manufacturers consistently earn higher marks for quality, reliability, and customer satisfaction, including Grand Design, Airstream, Tiffin, Newmar, and Winnebago, though they often come at higher price points reflecting better construction standards.

When you're ready to spend serious money on an RV, consider these alternatives:

Premium Quality Leaders

• Airstream: Iconic aluminum construction, excellent resale value, superior build quality
• Grand Design: Relatively new but consistently rated highly for construction and customer service
• Tiffin: Family-owned company known for reliability and strong customer support
• Newmar: Widely considered the best Class A manufacturer with top-tier craftsmanship

Solid Mid-Range Options

• Winnebago: Established brand with good warranty support and dealer network
• Lance: Well-built travel trailers with attention to detail
• Oliver Travel Trailers: Fiberglass construction, excellent durability
• Coachmen: Generally reliable across multiple RV types

Remember: even the best brands have occasional problems, and lower-tier brands sometimes produce excellent units. The key is understanding which manufacturers have systemic issues versus isolated incidents. Whatever brand you choose, proper maintenance is crucial—our RV maintenance guide helps you protect your investment regardless of manufacturer.

How Can I Inspect an RV Before Purchase to Avoid Problems?

Conduct a thorough multi-point inspection focusing on structural integrity, electrical systems, plumbing, appliances, and fit/finish details—preferably with an experienced RVer or professional inspector to catch issues that salespeople might gloss over.

Here's your inspection game plan:

Exterior Check

• Roof inspection: Look for cracks, punctures, or sealant issues (bring a ladder!)
• Wall condition: Check for soft spots, delamination, or wavy appearance
• Seals and caulking: Inspect around windows, doors, and roof fixtures
• Tire condition: Look for uneven wear that might indicate alignment issues

Interior Systems

• Test everything: Run all appliances, lights, outlets, and water systems
• Cabinet quality: Open/close all doors and drawers, check for loose hardware
• Floor integrity: Walk around, checking for soft spots or squeaks
• Slide-out operation: Test all slides multiple times if equipped

Documentation Review

• Service records: Ask for maintenance history and any warranty work
• Recall check: Verify any outstanding recalls have been addressed
• Title inspection: Ensure a clean title with no liens or flood damage

Don't let anyone rush you through this process. A reputable dealer will encourage thorough inspection, while pushback might be a red flag. For more detailed guidance, check out our comprehensive guide to buying used RVs, which covers additional inspection tips.

Should I Rent Before I Buy to Test Different Brands?

Absolutely—renting through platforms like Outdoorsy allows you to test specific models and brands in real-world conditions before making a major financial commitment, helping you understand both the RV lifestyle and individual brand characteristics.

This might be the smartest move you can make. Here's why renting first makes sense:

Real-World Testing

• Experience how different brands handle on the road
• Test living spaces, storage, and daily functionality
• Identify dealbreakers before you're stuck with payments
• Compare the build quality between manufacturers firsthand

Platform Options

Outdoorsy offers the largest selection of peer-to-peer rentals with up to $1 million insurance coverage and delivery options.

What to Test During Rental

• Driving characteristics: How does it tow or handle?
• Living comfort: Is the layout functional for your needs?
• System reliability: Do all appliances and systems work smoothly?
• Build quality: Notice any squeaks, rattles, or fit issues?

The cost of a week's rental is nothing compared to being stuck with the wrong RV for years. Plus, you'll have hands-on experience when talking to dealers—nobody can oversell you on features you've already tested. Our first-timer's guide to renting an RV covers everything from booking to insurance considerations.

Try Before You Buy—Then Protect Your Choice

Not every brand is perfect—before you commit, rent a similar model on Outdoorsy to see how it feels, then protect your short-list (or current rig) with a fast, personalized Roamly quote. We know the RV lifestyle because we live it too, and we'll help you find coverage that makes sense for how you actually use your rig.