fbanko..There's been a ton of talk about this in the past. During a span of time that included '07 & '08 (not sure of other years) Thor and some other RV mfr. used an inferior product. If I remember it correctly, Thor furnished the product to be used. I guess trying to save money. Why Flexsteel allowed their name to be put on this crappy product is beyond me, so they bear some of the blame if you ask me. There are a lot of us with the same problem you're having. From what I understand, Thor and others stopped using this product once the problems surfaced, but that doesn't help those of us with******on our chairs. Our sofa and other chair are fine.
For now, we have captain chair covers from CW. It's not worth the trouble or expense to us to have them replaced. Maybe some day.