Forest River XLR Toy Hauler Complaints

25 consumer complaints on file.

#11746256June 24, 2026
TIRES, STRUCTURE
The contact owns a 2024 Forest River XLR Toy Hauler equipped with Castle Rock Tires, Tire Line: ST Trailer and Wheel Radial, Tire Size: 225/75/R15, DOT Number: (N/A). The contact stated that while driving 65 MPH, three tires had blowouts, one after the other. The passenger’s side front and rear tires and the driver's front tire had experienced the blowouts. There was damage to the aluminum siding on the RV. No warning lights were illuminated. The contact was stranded for five hours before assistance was provided. A mobile tire service arrived and replaced the tires with Goodyear Endurance tires. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The tire failure mileage was 1,000. The vehicle mileage was unknown.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11728171March 31, 2026
SERVICE BRAKES
The failure involves the trailer brake wiring system. The brake wiring harness near the rear bathroom plumbing exit is improperly routed and installed in direct proximity to moving suspension components. This has resulted in repeated abrasion and damage to the brake wiring, causing intermittent and reduced braking capability. The affected components are available for inspection upon request. This condition presents a serious safety hazard. The trailer (approx. 18,000 lbs GVW) experienced degraded braking performance, significantly increasing stopping distance and risk of loss of control, particularly at highway speeds or during emergency braking. This creates a substantial risk to the operator, passengers, and the public. The defect has occurred multiple times and is reproducible. The brake wiring has been damaged on at least three separate occasions due to continued contact with suspension components. The failure location and mechanism have remained consistent, indicating a systemic design or manufacturing defect rather than normal wear or isolated damage. The condition has been visually confirmed during service and repair. Despite repeated failures, no permanent corrective action has been implemented by the manufacturer. There were no consistent warning indicators prior to failure. The primary symptom was reduced or inconsistent trailer braking, which progressed as the wiring became further compromised. Based on repeated failures and consistent damage location, this represents a design defect involving improper routing and inadequate clearance of critical safety systems. This condition may affect other similarly constructed units and warrants further investigation for potential recall or corrective action.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11722401March 6, 2026
STRUCTURE, TIRES
The contact owns a 2021 Forest River XLR Toy Hauler equipped with Castle Rock Tires, Tire Line: ST Tires, Tire Size: 225/75/R15, DOT Number: TJULT 1MT. While driving approximately 70 MPH, the RV suddenly started to swerve, and the steering wheel became unstable. The contact regained control of the steering wheel and parked the vehicle on the shoulder of the roadway. Upon inspection, it was discovered that there was tread separation on the rear passenger’s side tire. The spare tire was mounted to the RV, and the contact continued driving on the interstate when the front driver's side tire experienced a similar failure. The RV was driven to a tire shop, and all four tires were replaced. The contact stated that the RV was poorly constructed. The aluminum siding was unsecured, and the gray water tank was continuously leaking water into the RV. The cause of the failure was not yet determined, and the RV was not yet repaired. The manufacturer and local dealer were not contacted. The failure mileage was 8,500.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11711346January 16, 2026
ELECTRICAL SYSTEM, EQUIPMENT:RECREATIONAL VEHICLE/TRAILER, ELECTRICAL SYSTEM:WIRING
On 10/17/2025 while parked at Bethpage Campground in Urbanna, VA, the roof of our RV caught fire. The fire alarms did not sound the only indication was smoke filling the RV. Thankful this was during the day and we were awake. I felt the walls finding nothing hot then went outside and discovered the roof was on fire. I grab the fire extinguisher and climbed the ladder onto the roof and began putting out the fire. Attached are the pictures that show that there are screws/nails and a metal piece that goes through the wiring which caused the fire. I contacted Forest River and was told they would not cover any damages even though it was a manufacture defect and could have ending catastrophically if my family had been asleep.
Crash:
No
Fire:
Yes
Injuries:
0
Deaths:
0
#11678288August 4, 2025
EQUIPMENT:RECREATIONAL VEHICLE/TRAILER, FUEL SYSTEM, GASOLINE:STORAGE
My fuel station was not pumping fuel only air because the fuel pump line and fill neck vent hose line on the fuel station where installed from the manufacturer backwards not allowing the fuel to be picked up from the tank to the transfer pump. In an email from the fuel station manufacturer “Your particular unit came from Forest River Plant #79 and had a batch of these units where they installed the lines incorrect, not allowing the pump to pull any fuel.”
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11555965November 20, 2023
TIRES:TREAD/BELT, TIRES:SIDEWALL
This tire was mounted on my Forest River XLR Micro. The vehicle tires are rated for 2450lbs each @ 80 PSI. I was traveling with less than 8000lbs weight of the RV, and I had two of these tires blow out from the Sidewall/ tread area with in 20 miles of each other. This was the 3rd tire to blow out of the 5 original tires. I ALWAYS check my tire premeasure prior to traveling with my RV, and I know this trip I had 78-79 PSI cold. The tires were in very good shape, and had approximately 6400 miles on them. I have contacted the manufacture of tires, and they refused any warranty. I have also read online that other RVers have had the same issue with these tires. There should be a RECALL or something done.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11552736October 30, 2023
TIRES:TREAD/BELT, TIRES
Tire size: st 205 / 75 R 15 Returning ng home from a camping vacation. Traveling on interstate 10 east of San Antonio. Experienced a right rear blowout in a tandem axle camping trailer. Upon replacing damaged tire with included spare noticed considerable damage to wheel well from exploded tire. The tire’s tread had seperate exposing broken and separated belts. I was confused why brand new tires would explode as this one did. Also noticed that the 3 remaining tires looked different from the exact replacement spare tire. Spare tire looked normal but the three remaining tires looked like their center tread wanted to separate as well. We made it home. The tire is still available to inspect. Our lives were in danger because we had to pull over on the side of interstate and change tire. The tire was available for inspection by the insurance company but no comment was made.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11552192October 27, 2023
TIRES, TIRES:TREAD/BELT
ST225/75R15 Castlerock Tires by Lionshead. We actually had three of these tires fail on this vehicle in 2 seperate incidents within 5 weeks. I will file them seperately as it asks tire location and doesn't give option for multiple. In the incident in which the Rear Passenger Side Tire failed, we were driving about 60mph on Mississippi Highway towing the 2021 XLR Boost Toy hauler trailer with a Ram3500 dually around 3am. We had checked pressures and visually inspected the tires before leaving Tennessee at midnight. The tire tread blew apart leaving a large strip that spun and severely damaged the underside of the trailer and ripped off wire harness. We were forced to change the tire and tie up wires on the side of a busy highway in the dark with semi trucks passing us at 70mph plus. We definitely felt in danger and after finding delamination and missing tread on second tire found ourselves stranded in Mississippi sleeping in GoodYear parking lot after "limping" 30 miles in the middle of the night. Sleeping in parking lots in random cities where you don't know anyone is also risky in my opinion. I had all 5 tires replaced at that time to avoid future issues. I have reached out to the manufacturer of both the tires and the trailer 2 days ago and have had no response at this time. There were no warning signs or lights before the tire blew, it seemed to be going smooth on paved highway. The trailer was not overloaded, at the time of this incident we did not have our motorcycles loaded in toy hauler, just clothes & food etc..
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11552196October 27, 2023
TIRES, TIRES:TREAD/BELT
Lionshead Castlerock ST225/75R15 Tires on XLR Boost Toy Hauler Trailer. Within 5 weeks we had 3 tires fail in 2 incidents. I have already filed on the 2nd incident, but since it asks for tire location I am filing this second complaint for first incident. In the incident in which the front passenger side tire failed, we were traveling along Hwy 2 outside of Monroe Washington headed up Stevens Pass to a campground in Eastern Washington. The tire blew out traveling about 55mph on a paved highway. When it blew a large section of tread turned into a flap that damaged the underside of the trailer tearing off insulation and vapor barrier. We had to change the tire on the side of the road with traffic passing dangerously close. Since it was almost dark when we were done and we did not have a second spare in case of another incident we took it slow up pass and had to sleep in a rest are until tire shop opened. It was dangerous changing tire on the side of the busy road and nerve wrecking crossing pass without spare, however at that time (5 weeks ago) we did not bother with reporting or contacting mfg. as we thought it was a isolated incident and maybe we ran over something. When we had 2 more tires fail within such a short time leaving us stranded again with more damage we realized this is probably a defective tire situation. At this time we have reached out to the mfg of both the tire and trailer but have not heard anything back. We had this tire replaced by Les Schwab in Wenatchee WA and put it back as the spare. There was no warning before the blowout and we check pressure and visually inspect tires regularly. This was only about about 30 miles into our cross country trip.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11552199October 27, 2023
TIRES, TIRES:TREAD/BELT
Lionshead Castlerock st225/75r15 tire. We had 3 tires fail in 5 weeks, I filed seperate reports on the two that caused damage and high risk situations since it asks location of tire and doesn't give multiple as an option so I will focus on just this one in this report. We found the missing tread and delamination when we inspected and replaced this tire after the other 2 blowouts. This did cause a risky situation as we had to drive on damaged tire for 30 miles in the dark to find a dealer and sleep in their parking lot util they opened since we had already used our spare on the blow tire. At this time we have contacted the mfg of both the tires and trailer, filing warrantee paperwork with Lionshead. We have not heard anything back from them as of today.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11529767June 30, 2023
EQUIPMENT, ELECTRICAL SYSTEM, TRAILER HITCHES
The contact owns a 2022 Forest River XLR Toyhauler. Before purchasing the Toy Hauler, the contact noticed that the coupler had severe rust and was improperly welded. Upon investigation, the contact discovered NHTSA Campaign Number: 22V143000 (Equipment, Trailer Hitch) which she linked to the failure. The dealer agreed to make the needed repairs; however, upon delivery of the Toy Hauler, the coupler was spray painted to hide the damage and was not replaced. One day while using the microwave, the contact saw white smoke coming from the walls of the Toy Hauler and flames started coming from the walls. The contact used a fire extinguisher to put out the flames. The contact called the Fire Department who confirmed that the fire was caused by the electrical wiring inside the wall. A fire report was filed. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 22V135000 (Electrical System, Equipment). In addition, upon the use of the awning, the left side of the awning snapped and struck contact on the head. The contact was knocked unconscious but regained consciousness moments later. Medical attention was not sought. The contact linked the failure to NHTSA Campaign Number: 22V556000 (Equipment). The dealer and the manufacturer were notified several times of the failure but offered no assistance. The RV was not repaired. The failure mileage was unknown.
Crash:
No
Fire:
Yes
Injuries:
1
Deaths:
0
#11517529April 17, 2023
POWER TRAIN
WE PURCHASED THIS RV 0N 1-25-2022 FROM DAY BROS RV SALES 3054 SOUTH LAUREL RD LONDON KY 40744 WE TOOK THE RV ON OUR FIRST VACATION TO FL IN FEB 2023 ON OUR WAY HOME FROM VACATION IN NORTH CAROLINA BOTH WHEELS CAME OFF THE RV WE ALMOST JACK KNIFED, THE WHEEL STUDS ON BOTH WHEELS BROKE OFF WE WERE STRAYED ON 95 NORTH FOR OVER 4 HOURS SITTING ON THE SIDE OF THE ROAD, A TROOPER STOPPED BY 45 MINUTES AFTER WE BROKE DOWN WE FINALLY GOT TOWED OF THE ROAD IT WAS ON SATURDAY FEB 25 2023 . THE TROOPER RECOMMENED MANGUMS TOWING AND ROAD SERVICES THEY REPLACES THE WHEEL HUBS NEW RIMS AND TIRES AT A COST OF 2010.69 WHICH I HAVE THE BILL FOR PLUS PICTURES OF THE BROKEN WHEEL STUDS THE DEALERSHIP HAS STILL NOT SAID ANYTHING ABOUT THIS PROBLEM PLUS THE 2010.69 FOR REPAIRS WE HAD TO LEAVE THE RV IN NORTH CAROLINA SO THEY COULD FIX IT WE HAD TO RENT ANOTHER VEHICLE TO GO HOME WHICH IS IN DELAWARE 6 HOURS AWAY A WEEK LATER WE PICKED THE RV UP CAN YOU PLEASE LOOK INTO THIS MATTER A BRAND NEW RV SHOULD NOT LOSE IT WHEELS PERIOD
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11477380August 3, 2022
TIRES:TREAD/BELT, TIRES, TIRES:SIDEWALL
Multiple Tires: On highway travelling 55 - 60 mph when the tire blew on trailer. Tread went flying onto highway and damaged the underneath and side of the trailer. We checked tire pressure before we left on our short trip. Tires had minimal usage (estimated 1500 miles total). This was the worst one but on same trip another tire failed where tread separated from tire on 7/29/22. I have included photos of both and spare on trailer now with indicative info. The first flat however we were notified by passerby and were able to pull off highway and change the tire before any damage. Once we arrived home, my husband noticed another tire is warped. This is a total failure of these tires requiring all to be replaced. These tires should not be on the road. We are lucky nobody was hurt, injured or killed.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11464889May 16, 2022
STRUCTURE:BODY, ELECTRICAL SYSTEM, UNKNOWN OR OTHER
Electrical breakers continue to trip. Trim issues throughout along with floor bulking in kitchen. Both slides on on right side of camper leak when it rains. First trip out landing jacks did not work to level unit and one of the back glasses in the toy hauler scattered going down the road which was replaced with warranty. We have been trying to get the slide issue looked into for a couple of months but no luck getting a forest river tech to come assess and fix with the additional warranty purchased along with this unit. Have contacted manufacturer and was not helpful, they only referred places to carry to and would reimburse "some" of the cost. We are paying for a camper unit that is not up to standard for the price we paid for it especially having to wait 8 months after ordering it in June 2021 and we finally was able to pick up end of February 2022.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11432858September 14, 2021
STRUCTURE:BODY, ELECTRICAL SYSTEM
The contact owns a 2021 Forest River XLR ToyHauler. The contact stated that there was a dent in the roof which allowed water into the trailer. The water leakage caused a shortage in the electrical system. The contact had not taken the trailer to the dealer. The manufacturer was not made aware of the failure. The approximate failure mileage was 1,800.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11432275September 9, 2021
SUSPENSION:MULTIPLE AXLE
The contact owns a 2021 Forest River XLR Toy Hauler. The contact stated that while her husband was driving 65 MPH, the rear driver’s side tire on the toy hauler detached from the vehicle without warning. The contact's husband was able to pull off the highway and a fellow motorist explained to them that the tire had detached from the toy hauler and rolled across the freeway and ricocheted off the divider. A highway patrol officer assisted her and her husband in attempting to find the tire; however, the tire was never found. The contact was able to remove the drum from the trailer and drove to an independent mechanic and had the tire replaced. The following day while her husband was driving at 60 MPH, another motorist notified them that another tire on the toy hauler was defective. The contact's husband pulled over and upon inspection he discovered that a bubble had formed on the front passenger’s side tire and that the rear passenger tire was severely worn. Her husband once again detached the toy hauler and replaced both tires. Due to the multiple tire failures on the vehicle, the contact and her husband determined that the failure may be linked to the axle and not the actual tires. All three defective tires were replaced. The vehicle was not inspected or diagnosed. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 2,000.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11432130September 8, 2021
WHEELS:HUB
The contact owns a 2021 Forest River XLR Toy Hauler. The contact stated while driving at an undisclosed speed, the vehicle fishtailed, spun around, and the driver noticed that the wheels were detached, and trailer was resting on the hub. The contact stated that the wheels were not installed properly. The contact called the local dealer, but vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was unknown.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11424766July 14, 2021
TIRES
The contact owns a 2017 Forest River Fury ToyHauler equipped with Power King tires, Tire Line: Towmax STR, Tire Size: 225/75/R15, DOT Number: 1ADB4-TBT1-4017 trailered to a 2002 Ford F-250. While driving approximately 65 MPH, the front passenger’s side tire experienced a blowout. The front and rear passenger’s side trailer tires were replaced by an independent mechanic. Approximately two years later, the rear driver’s side trailer tire also experienced a blowout. The contact had the driver’s and passenger’s side tires replaced by an independent mechanic. Recently, the contact stated that the same front passenger’s side tire experienced another blowout while driving approximately 60-65 mph. The contact took the vehicle to another independent mechanic where he replaced all four tires on the trailer. The contact stated that each blowout had caused severe damages to the rear portion of the trailer. The contact attempted to reach the tire manufacturer but was unsuccessful. The approximate failure mileage for the first tire was 2,000. The subsequent tire failure mileages were 1,000 and 3,500 respectively. The vehicle failure mileage was unknown.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11423129July 1, 2021
ELECTRICAL SYSTEM
The contact owns a 2021 Forest River XLR. The contact stated that the automatic leveling system for the RV suddenly failed, causing the front leveling legs of the RV to collapse. As a result, the vehicle collapsed to the ground. There were no injuries sustained. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure but did not provide any assistance. The vehicle was not repaired. A failure mileage was unknown.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0
#11416749May 15, 2021
FUEL/PROPULSION SYSTEM
PROPANE LINE LOCATION IN TIRE WELL. TIRES RUBBED HOLE IN PROPANE LINE CAUSING A PROPANE LEAK. WE DRIVE WITH PROPANE OFF. GOT TO CAMPSITE AND TURNED PROPANE ON. WITHIN A HALF HOUR SMELLED PROPANE REALLY BAD. TURNED OFF PROPANE. CALLED RV REPAIR AND THEY FOUND THE LEAK. THIS IS A DANGEROUS DESIGN FLAW.
Crash:
No
Fire:
No
Injuries:
0
Deaths:
0

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