This Problem Across All Years
Excessive Frame Flex/Failure& Structure I am reporting multiple serious structural and safety issues with my Grand Design RV that appear consistent with excessive frame flex and failure, as outlined in NHTSA Investigation PE24029. These include: Significant movement of front bedroom cabinets during travel, indicating internal structural instability of the walls. Large gaps in both the interior and rear toy hauler doors, which compromise insulation and safety concerns. Cracked and misaligned front entry door, even after manufacturer replacement. Generator compartment door fails to lock properly, likely due to excessive frame flex/frame misalignment. Screws popping out of the front cap and a visible crack in the front cap corner. Bedroom slide failure due to internal twisting. Main slide floor detaching from the bottom. Persistent latching issues with the main entry door, even when the RV is perfectly level. These issues not only affect the usability of the RV but also pose serious safety risks while in transit. The structural instability could lead to doors opening unexpectedly, slideouts extending, or components detaching on the road—endangering both occupants and other drivers. I urge the NHTSA to include this case in its ongoing investigation and to consider a recall or mandatory corrective action for affected Grand Design RVs.
Excessive Frame Flex/Failure& Structure I am reporting multiple serious structural and safety issues with my Grand Design RV that appear consistent with excessive frame flex and failure, as outlined in NHTSA Investigation PE24029. These include: Significant movement of front bedroom cabinets during travel, indicating internal structural instability of the walls. Large gaps in both the interior and rear toy hauler doors, which compromise insulation and safety concerns. Cracked and misaligned front entry door, even after manufacturer replacement. Generator compartment door fails to lock properly, likely due to excessive frame flex/frame misalignment. Screws popping out of the front cap and a visible crack in the front cap corner. Bedroom slide failure due to internal twisting. Main slide floor detaching from the bottom. Persistent latching issues with the main entry door, even when the RV is perfectly level. These issues not only affect the usability of the RV but also pose serious safety risks while in transit. The structural instability could lead to doors opening unexpectedly, slideouts extending, or components detaching on the road—endangering both occupants and other drivers. I urge the NHTSA to include this case in its ongoing investigation and to consider a recall or mandatory corrective action for affected Grand Design RVs.
frame failure and structural issues
frame failure and structural issues
2019 Grand Design Momentum 397ms (VIN: [XXX] ) I am having to file this NHTSA (potential frame failure) complaint with assistance from Pete West, who is acting as my RV consumer advocate due to the fact that my husband, who was unarmed snd violently shot and killed on [XXX], by an off-duty Ft. Lauderdale police officer, right in front of me in our RV park over an RV park management dispute. I have reached out to Pete West ([email protected]) for his assistance with this. Our/my RV was purchased “used” from General RV in June 2024. There are a wide variety of other non-related issues to this complaint that will be addressed with the dealership and Grand Design directly. Front main door comes open during transport Cargo doors have also come open during transport and had to resecure them. Slide-outs do partially come out during transport Upon hitching truck up to the pin box noticing pin box movement up into the upper deck (unclear about amount of pin box movement). We have also noticed electrical outlets (kitchen island and bedroom) got burned out for no foreseeable reason (inoperative) and concerned about potential fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
2019 Grand Design Momentum 397ms (VIN: [XXX] ) I am having to file this NHTSA (potential frame failure) complaint with assistance from Pete West, who is acting as my RV consumer advocate due to the fact that my husband, who was unarmed snd violently shot and killed on [XXX], by an off-duty Ft. Lauderdale police officer, right in front of me in our RV park over an RV park management dispute. I have reached out to Pete West ([email protected]) for his assistance with this. Our/my RV was purchased “used” from General RV in June 2024. There are a wide variety of other non-related issues to this complaint that will be addressed with the dealership and Grand Design directly. Front main door comes open during transport Cargo doors have also come open during transport and had to resecure them. Slide-outs do partially come out during transport Upon hitching truck up to the pin box noticing pin box movement up into the upper deck (unclear about amount of pin box movement). We have also noticed electrical outlets (kitchen island and bedroom) got burned out for no foreseeable reason (inoperative) and concerned about potential fire. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Frame failure on fifth wheel deck. Noticed when hooking RV to tow vehicle that the pin box would move upward roughly 1 inch. Also when hitched to tow vehicle would notice that all cabinets in front bedroom would move to the point of damaging walls and causing the doors to bind and hit the ceiling. Once I learned of many other Grand Design RV owners having this same problem, I removed the front skin to expose the frame of the rv and found that welds had completely broken, steel angle gussets sheared, along with finding the upper fifth wheel deck welds completely broke free of the upright supports on the passenger side of the rv. With the broken steel and broken welds, the only way the camper stayed together while towing was by way of the fiberglass skin of the walls. Also found that the steel deck plates designed to bolt to the rv walls had less than half the bolts (due to more than half the available holes not have a bolt installed), out of the existing bolts they were either sheared or severely bent. I contacted Grand Design and provided the pictures to show the damage and they requested that I tow the RV to an approved repair shop. Due to safety concerns I explained that I would not tow the RV anywhere in this condition. Problem was confirmed by Owen Bailey with Grand Design through the pictures supplied by me. No warning was given other than the interior damage from the frame flexing.
Frame failure on fifth wheel deck. Noticed when hooking RV to tow vehicle that the pin box would move upward roughly 1 inch. Also when hitched to tow vehicle would notice that all cabinets in front bedroom would move to the point of damaging walls and causing the doors to bind and hit the ceiling. Once I learned of many other Grand Design RV owners having this same problem, I removed the front skin to expose the frame of the rv and found that welds had completely broken, steel angle gussets sheared, along with finding the upper fifth wheel deck welds completely broke free of the upright supports on the passenger side of the rv. With the broken steel and broken welds, the only way the camper stayed together while towing was by way of the fiberglass skin of the walls. Also found that the steel deck plates designed to bolt to the rv walls had less than half the bolts (due to more than half the available holes not have a bolt installed), out of the existing bolts they were either sheared or severely bent. I contacted Grand Design and provided the pictures to show the damage and they requested that I tow the RV to an approved repair shop. Due to safety concerns I explained that I would not tow the RV anywhere in this condition. Problem was confirmed by Owen Bailey with Grand Design through the pictures supplied by me. No warning was given other than the interior damage from the frame flexing.
Welds on the frame where the fifth wheel overhang attaches to the main frame have broke allowing the kingpin to raise up off of the front upright. This means that the kingpin overhang is only attached at the rear upright making the RV unsafe to tow.
Welds on the frame where the fifth wheel overhang attaches to the main frame have broke allowing the kingpin to raise up off of the front upright. This means that the kingpin overhang is only attached at the rear upright making the RV unsafe to tow.
my suspension failed with the leaf springs breaking and the shackles and bushings failed then the frame is breaking( flexing). all fasteners were loose and some missing the body came loose from the frame... this is a issue with many other grand design 5th wheels ... hopefully the parts that fell off on the freeway did not hurt anyone... ( leaf springs)
my suspension failed with the leaf springs breaking and the shackles and bushings failed then the frame is breaking( flexing). all fasteners were loose and some missing the body came loose from the frame... this is a issue with many other grand design 5th wheels ... hopefully the parts that fell off on the freeway did not hurt anyone... ( leaf springs)
Broken frame where the pin box is the hitch part that connects to the truck very very unsafe
Broken frame where the pin box is the hitch part that connects to the truck very very unsafe
The kitchen side slide out hydraulic cylinder burst/ruptured while under pressure due to the incorrect length bolt being used in the slide out rotating cross shaft. The bolt wore a hole in the cylinder over a 3 year period, and the cylinder shot hydraulic fluid all over the under belly of the trailer. Hydraulic fluid sprayed several 120-volt and 12-volt electrical connections and wires, and also leaked out of the side of the chloroplast. The fluid would have leaked onto the wheels and brakes if it had been in motion when the cylinder failed. Also, the entire hydraulic system is combined, so this caused a total loss of pressure in the front landing gear/jacks and leveling system. So many possible safety issues with this. Grand Design acknowledged the issue and reimbursed me for the parts, but I feel obligated to report this. It actually happened when the new owner (I just sold it) came to pick up the trailer. Others on an internet discussion group found the exact same issue.
The kitchen side slide out hydraulic cylinder burst/ruptured while under pressure due to the incorrect length bolt being used in the slide out rotating cross shaft. The bolt wore a hole in the cylinder over a 3 year period, and the cylinder shot hydraulic fluid all over the under belly of the trailer. Hydraulic fluid sprayed several 120-volt and 12-volt electrical connections and wires, and also leaked out of the side of the chloroplast. The fluid would have leaked onto the wheels and brakes if it had been in motion when the cylinder failed. Also, the entire hydraulic system is combined, so this caused a total loss of pressure in the front landing gear/jacks and leveling system. So many possible safety issues with this. Grand Design acknowledged the issue and reimbursed me for the parts, but I feel obligated to report this. It actually happened when the new owner (I just sold it) came to pick up the trailer. Others on an internet discussion group found the exact same issue.
WE WERE IN ROUTE TO ASSATEAGUE FOR THE WEEKEND WHEN OUR AWNING SOMEHOW OPENED & DETACHED FROM OUR CAMPER WHILE DRIVING AT HIGHWAY SPEED ON RT 50 IN MARYLAND. I BELIEVE IT FAILED DUE TO BEING BLOWN OPEN BY THE WIND, BUT I AM UNSURE. WHEN IT DETACHED, IT VIOLENTLY FLAILED AROUND DAMAGING THE EXTERIOR OF THE TRAILER. WE WERE ON THE CHESAPEAKE BAY BRIDGE WHEN THE EVENT OCCURRED WITH THE AWNING FLAILING AROUND BY CARS & THE BRIDGE STRUCTURE. AS SOON AS I HEARD THE SOUND, I IMMEDIATELY DROPPED OUR SPEED TO A CRAWL & STARTED LOOKING AROUND AND SAW THE AWNING FLAILING AROUND VIOLENTLY ON BOTH SIDES OF THE CAMPER. WHEN IT BECAME DETACHED IT STRUNG OVER THE TOP OF THE CAMPER TO THE OTHER SIDE, NOW HANGING OVER ON BOTH SIDES. OTHER DRIVERS WHO WITNESSED WHAT HAPPENED GAVE US SPACE AND WE WERE ABLE TO GET OFF THE BRIDGE & OFF THE ROAD SAFELY WITHOUT HITTING ANY VEHICLES. WE ARE UNCLEAR WHY IT CAME DISCONNECTED FROM THE CAMPER. AS ALWAYS, WE PREFORMED OUR PRE-TRIP INSPECTIONS, AND EVERYTHING WAS CLOSED AND SECURE. AT THE TIME OF THE FAILURE, WE HAD ALREADY BEEN ON THE ROAD FOR OVER 2 HOURS AND EVERYTHING WAS AS NORMAL. WE BELIEVE THERE WAS A FAILURE WITH THE DESIGN OR HARDWARE WHICH ALLOWED THE WIND TO OPEN THE AWNING CREATING A PARACHUTE LIKE EVENT AND THE SUBSEQUENT DAMAGE. IT IS A MIRACLE THAT NO OTHER VEHICLES WERE DAMAGED & THAT I WAS ABLE TO CONTROL THE TRUCK & TRAILER ON THE BRIDGE. AFTER WE REACHED OUR DESTINATION, WE SEARCHED THE INTERNET FOR ISSUES SUCH AS THIS & LOW & BEHOLD THIS IS A COMMON OCCURRENCE. HTTPS://WWW.RV.NET/FORUM/INDEX.CFM/FUSEACTION/THREAD/TID/27277249/PRINT/TRUE.CFM. WE TOOK THE COACH THE NEXT BUSINESS DAY TO BECKLEY'S RV & WERE ADVISED BY THE SHOP FOREMAN THAT HE HAS SEEN THIS HAPPEN OVER 100 TIMES. WHAT!!! I FEEL THAT MY FAMILY, OR OTHERS COULD HAVE BEEN SERIOUSLY HURT & OR KILLED WITH THIS EVENT. *DT*JB
WE WERE IN ROUTE TO ASSATEAGUE FOR THE WEEKEND WHEN OUR AWNING SOMEHOW OPENED & DETACHED FROM OUR CAMPER WHILE DRIVING AT HIGHWAY SPEED ON RT 50 IN MARYLAND. I BELIEVE IT FAILED DUE TO BEING BLOWN OPEN BY THE WIND, BUT I AM UNSURE. WHEN IT DETACHED, IT VIOLENTLY FLAILED AROUND DAMAGING THE EXTERIOR OF THE TRAILER. WE WERE ON THE CHESAPEAKE BAY BRIDGE WHEN THE EVENT OCCURRED WITH THE AWNING FLAILING AROUND BY CARS & THE BRIDGE STRUCTURE. AS SOON AS I HEARD THE SOUND, I IMMEDIATELY DROPPED OUR SPEED TO A CRAWL & STARTED LOOKING AROUND AND SAW THE AWNING FLAILING AROUND VIOLENTLY ON BOTH SIDES OF THE CAMPER. WHEN IT BECAME DETACHED IT STRUNG OVER THE TOP OF THE CAMPER TO THE OTHER SIDE, NOW HANGING OVER ON BOTH SIDES. OTHER DRIVERS WHO WITNESSED WHAT HAPPENED GAVE US SPACE AND WE WERE ABLE TO GET OFF THE BRIDGE & OFF THE ROAD SAFELY WITHOUT HITTING ANY VEHICLES. WE ARE UNCLEAR WHY IT CAME DISCONNECTED FROM THE CAMPER. AS ALWAYS, WE PREFORMED OUR PRE-TRIP INSPECTIONS, AND EVERYTHING WAS CLOSED AND SECURE. AT THE TIME OF THE FAILURE, WE HAD ALREADY BEEN ON THE ROAD FOR OVER 2 HOURS AND EVERYTHING WAS AS NORMAL. WE BELIEVE THERE WAS A FAILURE WITH THE DESIGN OR HARDWARE WHICH ALLOWED THE WIND TO OPEN THE AWNING CREATING A PARACHUTE LIKE EVENT AND THE SUBSEQUENT DAMAGE. IT IS A MIRACLE THAT NO OTHER VEHICLES WERE DAMAGED & THAT I WAS ABLE TO CONTROL THE TRUCK & TRAILER ON THE BRIDGE. AFTER WE REACHED OUR DESTINATION, WE SEARCHED THE INTERNET FOR ISSUES SUCH AS THIS & LOW & BEHOLD THIS IS A COMMON OCCURRENCE. HTTPS://WWW.RV.NET/FORUM/INDEX.CFM/FUSEACTION/THREAD/TID/27277249/PRINT/TRUE.CFM. WE TOOK THE COACH THE NEXT BUSINESS DAY TO BECKLEY'S RV & WERE ADVISED BY THE SHOP FOREMAN THAT HE HAS SEEN THIS HAPPEN OVER 100 TIMES. WHAT!!! I FEEL THAT MY FAMILY, OR OTHERS COULD HAVE BEEN SERIOUSLY HURT & OR KILLED WITH THIS EVENT. *DT*JB