Thor aria entry door extension popping

[Our20th]

I have a 2022 Thor Aria 3901 that has a Challenger Entry door. The problem that I am experiencing is that the door is designed to extend beyond 90 degrees to almost 120 degrees. When this occurs the door makes a loud popping noise. The extension control mechanism is mounted internally mid way down the door on the hinge side. I have spoke to Challenger, Thor, Lippert, and the RV techs at the dealership about this issue all with the same answer that there is no fix.
I have taken the inner panel off the door and see that there is some sort of spring loaded clamp that is suppose to control the door extension. It obviously does a poor job of that. The only temporary cure that I have found is to pack that spring clamp housing with wheel bearing grease to eliminate the noise.
I have seen some retrofits on other brand Class A's removing the scissor extension for a gas strut mounted externally to control the opening extension. I am looking for any info from anyone that has done this successfully with the round radius entry door on a Thor Aria 3901 OR any suggestion how to correct this manufacturing error.

Thank You

[Country Road]

Originally Posted by Our20th

I have a 2022 Thor Aria 3901 that has a Challenger Entry door. The problem that I am experiencing is that the door is designed to extend beyond 90 degrees to almost 120 degrees. When this occurs the door makes a loud popping noise. The extension control mechanism is mounted internally mid way down the door on the hinge side. I have spoke to Challenger, Thor, Lippert, and the RV techs at the dealership about this issue all with the same answer that there is no fix.
I have taken the inner panel off the door and see that there is some sort of spring loaded clamp that is suppose to control the door extension. It obviously does a poor job of that. The only temporary cure that I have found is to pack that spring clamp housing with wheel bearing grease to eliminate the noise.
I have seen some retrofits on other brand Class A's removing the scissor extension for a gas strut mounted externally to control the opening extension. I am looking for any info from anyone that has done this successfully with the round radius entry door on a Thor Aria 3901 OR any suggestion how to correct this manufacturing error.

Thank You

I agree that the noise would be annoying. Someone certainly will comment and hopefully give you some ideas on how to remedy the problem. Have you personally looked at another coach with a similar door setup for comparison to see if yours perhaps is malfunctioning?

You may want to ask this question on the Thor Industries Forum here on IRV2.

[Bigd9]

Does yours look like this one?

[theroc]

Huh! You have a new coach. I figured that problems like that would have been solved by now.

I know back years ago, it was a very common problem especially on Winnebago coaches and some Fleetwoods. I had 2 Winnebago products that had the problem back in the mid-2000s.

Read through this thread on the Winnie Owner's Forum and see if there's anything you can get out of the information given there if it pertains to your problem (I think both Scott and Paul are still active on this forum so maybe they'll chime in):

'04 Horizon, entry door "Pop" when opening, don't think it's normal

[Our20th]

Originally Posted by Bigd9

Does yours look like this one?

Yes, exactly like that. I had that same device in my previous 2018 Holiday Rambler.

[Our20th]

I did post it first on the Thor Forum and did not receive any guidance as of yet

[Bigd9]

That is a Atwood Door Check. They do sell them. Here is a screen copy I did several years ago. However I don't see it listed anymore. THere are several versions of this check, so be careful if you decide to replace it.

On mine, the popping noise comes from there the latch hooks to the frame. There is a pin, and the hole there the pin goes elongates. You can check to see if that is your problem by putting some grease in the hole and see if the pop noise lessens. Unfortunately it won't last long and the POP will return.

Even owners who replaced the door check have reported the new door check started to do the same thing a year or so after replacement.

[Our20th]

Thanks for the help. I appreciate the info.